Assessment Cover Sheet
Assessment Title Practical Design Project
Assessment Type Uncontrolled Group Not must-pass
Due Date 29 March 2026 Course Code EN8906
Course Title Vibration, Noise and Mechanics of Machines
Internal Moderator’s Name Dr. C. Subramanian
External Examiner’s Name Dr. Sikiru Louwarotimi, Ismail
Instructions:
1. This cover sheet must be completed (section in blue below) and attached to your assessment before
submission in soft copy.
2. The time allowed for this assessment is 30 days.
3. This assessment carries 100 marks distributed to a total of 1 practical project report assessing CILO
2.
4. The materials allowed for use in this assessment are uploaded in Moodle.
5. The use of generative AI tools is strictly prohibited.
6. References consulted (if any) must be properly acknowledged and cited.
7. The assessment has a total of 8 pages.
Learner ID Date Submitted
Learner Name
Programme Code
Programme Title
Lecturer’s Name Dr Abdelgadir Abdelghani
By submitting this assessment for marking, I affirm that this assessment is my own work.
Learner Signature
Do not write beyond this line. For assessor use only.
Assessor’s Name
Marking Date 29/03/2026 Maks Obtained
Comments:
Practical Design Group Project
Design of a Two-Stage Industrial Gearbox for Conveyor Application
Assessment Weight: 35% (100 Marks)
Due date: 29 March 2026
Learning Outcomes (CILO 2):
To critically analyze transmission elements to select appropriate components, such as gears,
geartrains, belt drives shafts and bearings
- Please ensure that all engineering calculations and supporting technical details related to your
gearbox design are clearly presented in the report.
- Calculations should be shown at the relevant sections where they are required to support your
design decisions.
- Any extended calculations, supplementary analyses, or detailed derivations that may interrupt the
flow of the main report should be included in the Appendix and properly referenced within the
report.
1. Project Overview
This project requires students to design a two‑stage spur gear speed reduction gearbox suitable for
Conveyor Application. The project integrates analytical gear design, shaft design, bearing selection,
and CAD system modeling into a complete mechanical design task.
The project emphasizes engineering judgment, adherence to recognized standards (AGMA, ASME),
and professional documentation consistent with industrial practice.
2. Design Problem Statement
Design a two‑stage compound spur gear speed reducer that:
- Accepts input from an electric motor operating at 1500 rpm
- Delivers an output speed between 120–130 rpm
- Students should present a center distance table as part of their design calculations.
- Transmits power equal to the average of the last two digits of each group member’s student ID
(kW):
For example: Group 3 (201903113, 201801345,2 01802495)
Average = (13+45+95)/3 =51kW
- Uses spur gears with a 20° pressure angle
The gearbox must be designed as an integrated mechanical system including gears, shafts, bearings,
and housing.
3. Design Requirements
3.1 Transmission Ratio Design
- Determine the total transmission ratio required to achieve the specified output speed range.
- Distribute the ratio optimally across two stages, ensuring balanced load sharing, reasonable gear
sizes, manufacturability, and efficient power transmission.
- Provide engineering justification for the selected ratio distribution strategy.
3.2 Gear Design (AGMA-Based)
- Select an appropriate module using the AGMA method.
- Perform analytical calculations to determine gear geometry, bending stress, and contact stress.
- Ensure compliance with AGMA safety recommendations.
- Clearly state and justify all assumptions.
3.3 Gear Material and Heat Treatment
- Select suitable gear material(s).
- Specify appropriate heat treatment process (if applicable).
- Justify selection based on strength, wear resistance, fatigue resistance, and manufacturability.
3.4 Shaft Design (ASME Code)
- Design all shafts using the ASME code for shaft design.
- Consider combined torsion and bending loading.
- Include gear tooth forces and stress concentration effects.
- Verify factor of safety and justify shaft diameters.
3.5 Bearing Selection and Life Verification
- Determine radial (and axial if applicable) loads on bearings.
- Select appropriate bearings using a recognized manufacturer catalogue.
- Verify bearing life using L10 life calculation.
- Clearly reference the selected catalogue.
3.6 Gearbox Efficiency Estimation
- Estimate individual stage efficiency.
- Compute overall gearbox efficiency.
- Discuss power losses and practical implications.
3.7 CAD Development
- Develop complete 3D CAD assembly including gears, shafts, bearings, housing, and fasteners.
- Provide assembled model, exploded view, Bill of Materials (BOM), and sectional assembly
drawing.
- Ensure drawings follow standard engineering drafting conventions.
3.8 Engineering Justification
- Provide clear engineering justification for all major design decisions including ratio
distribution, module selection, material choice, shaft dimensions, bearing selection, and
structural layout.
4. Project Deliverables
- Technical Design Report (PDF format)
- Complete CAD assembly files
- Sectional assembly drawing (PDF)
- Bill of Materials (BOM)
5. Report Structure
1. Introduction
2. Design Specifications
3. Transmission Ratio Determination
4. Gear Design (AGMA Method)
5. Material and Heat Treatment Selection
6. Shaft Design (ASME Code)
7. Bearing Selection and L10 Life Verification
8. Efficiency Estimation
9. CAD Assembly and Drawings
10. Engineering Discussion and Justification
11. Conclusions
12. Appendix
6. Assessment Criteria (100 Marks)
Assessment for the Gearbox Design Project will be divided into two main components:
- 40% – Technical Design Report
This component will evaluate the quality and completeness of your written
submission, including the engineering calculations, design methodology, justification
of assumptions, adherence to design standards (e.g., AGMA, ASME), and the clarity
of technical presentation.
Component Marks
Transmission ratio design and distribution 10
AGMA gear design and module selection 20
Gear material and heat treatment justification 10
Shaft design (ASME method) 15
Bearing selection and L10 life verification 15
Efficiency estimation 5
CAD assembly, BOM and sectional drawing 15
Engineering justification and report quality 10
Total 100
Weightage 40%
- 60% – Project Presentation
This component will assess your ability to clearly communicate your design approach,
explain the engineering decisions made during the design process, justify calculations
and selections (gears, shafts, bearings, materials, etc.), and respond effectively to
questions during the presentation and discussion.
7. Submission
Each group should submit the design report through Turnitin.
Refer class notes, Faculty presentation in Moodle and AGMA standards for the design.
8. Academic Integrity
All calculations must be independently performed by the group. Use of standard references and
catalogues is permitted but must be properly cited. Any form of academic misconduct will be
addressed according to institutional regulations.
9. Detailed Assessment Rubric
Total Marks: 100 (Report Component)
(Weight in course: 40% of project mark)
Poor (Incorrect
Max Excellent (Correct procedure Good (Correct procedure
Design Component procedure or major
Marks & correct results) with minor mistakes)
errors)
Correct total ratio calculation Incorrect ratio
Correct approach but
Transmission Ratio and well-justified distribution calculation or
minor numerical errors or
Determination and 10 between stages. Center distance unrealistic stage
weak justification.
Distribution table correctly presented. distribution.
(6–8.9)
(9–10) (0–5.9)
Correct AGMA design
Correct procedure but
procedure, proper module Incorrect design
AGMA Gear Design errors in calculations or
selection, gear geometry, approach or major
and Module 20 incomplete AGMA
bending and contact stress calculation errors.
Selection parameters. (
calculations. (0–11.9)
12–16.9)
(17–20)
Appropriate material and heat
Acceptable material
Gear Material and treatment selected with strong Poor or unjustified
selection but weak or
Heat Treatment 10 engineering justification material selection.
incomplete justification.
Selection (strength, wear, fatigue). (0–5.9)
(6–8.9)
(9–10)
Proper torque and bending Correct approach but
Incorrect design
calculations, correct shaft errors in loading
Shaft Design (ASME method or unrealistic
15 diameter using ASME code, calculations or safety
Method) shaft dimensions.
appropriate factor of safety. factor justification. (9–
(0–8.9)
(13–15) 12.9)
Correct load calculations, Correct procedure but
Incorrect bearing
Bearing Selection appropriate bearing selection minor calculation errors or
selection or missing
and L10 Life 15 from catalogue, L10 life incomplete catalogue
life verification.
Verification correctly verified. justification.
(0–8.9)
(13–15) (9–12.9)
Realistic estimation of stage
efficiency and overall gearbox Basic estimation but weak No clear efficiency
Efficiency Estimation 5 efficiency with discussion of justification. estimation.
losses. (2–3.9) (0–1.9)
(4–5)
Complete professional CAD
Assembly present but
CAD Assembly, assembly including exploded Poor or incomplete
incomplete drawings or
BOM and Sectional 15 view, sectional drawing, and CAD model.
missing details.
Drawing detailed BOM. (0–8.9)
(9–12.9)
(13–15)
Well-structured report with clear Poorly structured
Engineering Acceptable structure but
explanations, figures, references, report with unclear
Justification and 10 clarity or formatting
and professional presentation. explanations.
Report Quality issues. (6–8.9)
(9–10) (0–5.9)