Design of Transmission Systems — T.E.

Mechanical (2019 Pattern)

Unit 5
Design of M/C Tool Gear Box
Complete Theory Notes | Exam Ready | No Numericals

How to use: Topics are in syllabus order.

Stars show exam frequency: ★★★ = asked in 4-6 of 6 papers ★★ = 2-3 papers ★ = once

5.1 Introduction to Machine Tool Gear Box

A gear box is a mechanical device that transmits power from the prime mover (motor) to the machine
while changing speed and torque.
A machine tool (lathe, milling machine, drilling machine etc.) needs different spindle speeds for different
jobs — cutting speed depends on job diameter and material. A multi-speed gear box provides a set of
fixed stepped speeds to cover this entire range.

Types of Gear Boxes

• Sliding Mesh Gear Box — gears slide on splined shafts to mesh. Simple but noisy; requires
stopping to change speed.
• Constant Mesh Gear Box — all gears remain meshed; dog clutches select the ratio. Quieter, faster
to shift.
• Synchromesh Gear Box — like constant mesh but synchroniser rings match speeds before
engagement. Smooth and noiseless.

5.2 Basic Considerations in Design of Multi-Speed Gear Box ★★

Answer to: 'Explain basic considerations / State the importance of multi-speed gear box.' Write all 7
points.
• Speed range between two successive speeds should be 10-15%. A larger step reduces optimum
tool utilisation.
• A sufficient number of speed ratios should be available without stopping the machine.
• Operator should be able to change speeds without passing through intermediate steps.
• Due to compact design, axial length is least if gear clusters are sliding. A sliding cluster must
NOT have more than 3 gears.
• Only gears achieving the selected ratio should rotate — all other gears in the box should remain
stationary.
 • Number of shafts, gears and levers should be minimum — fewer parts = higher reliability.
• Control unit must be ergonomically designed — centralised with all controls accessible from one
place.

5.3 Laws of Speed Regulation — AP, GP, HP ★★★

Three laws decide the rpm values at each speed step. GP is always preferred for machine tools.

5.3.1 Arithmetic Progression (AP)

Speeds increase by a constant absolute difference d.
N1, N1 + d, N1 + 2d, N1 + 3d, ...

Advantages of AP
• Simple to understand and calculate.
• Equal absolute speed gap between consecutive steps.

Disadvantages of AP
• Speed ratio between successive steps is NOT constant — it decreases at higher speeds.
• At low speeds ratio is large (wasteful); at high speeds it is small — unequal loss of economic cutting
speed.
• Not suitable for machine tools.
• Gear ratios do not repeat — each stage needs unique gear pairs, making design complex.

5.3.2 Geometric Progression (GP) ★★★

Speeds increase by a constant ratio called the Progression Ratio phi.
N1, N1 x phi, N1 x phi^2, N1 x phi^3, ...
The ratio between any two successive speeds is always phi:
N2/N1 = N3/N2 = N4/N3 = phi (constant)

Key Formulae

Progression ratio: phi = (N_max / N_min)^(1 / (z - 1))

Range ratio: R = N_max / N_min = phi^(z-1)
Speed at step n: N_n = N_min x phi^(n-1)
Standard phi values: 1.06 | 1.12 | 1.25 | 1.41 | 1.58 | 1.78 | 2.0

Advantages of GP
• Constant percentage loss of cutting speed — speed ratio is the same at every step, so machining
efficiency is uniform across all speeds. This is the most important advantage.
• Gear ratios form a repeating pattern — the same gear pairs can be reused across stages,
simplifying design.
• Gear box is compact and standardised — directly based on preferred number (R) series.
• Most widely used in practice for all machine tool gear boxes.

Disadvantages of GP
• Calculations are more complex than AP.
• At lower speeds, absolute speed difference is very small — close spacing not always needed.
 • Must use standard phi values — limits design flexibility.

5.3.3 Harmonic Progression (HP)

In HP, the reciprocals of speeds are in AP.
1/N1, 1/N2, 1/N3, ... are in AP

Advantages of HP
• Speeds are more closely spaced at lower rpm — good for heavy cutting at low speeds.
• Better coverage of the low-speed range.

Disadvantages of HP
• Speed ratio between steps is not constant — unequal loss of cutting speed.
• Complex to analyse and design.
• Rarely used in modern machine tools.
• Gear ratios do not repeat — each stage needs unique gear pairs.

Comparison Table: AP vs GP vs HP ★★★

Parameter AP GP HP

Speed difference Constant (absolute) Constant ratio (%) Variable

Loss of cutting speed Unequal Equal (uniform) Unequal

Suitability for machine

Poor Best Moderate
tools

Complexity Simple Moderate Complex

Standard use Rarely used Always preferred Rarely used

Gear ratio pattern Non-repeating Repeating Non-repeating

5.4 Significance of Geometric Progression Ratio (phi) ★★★

phi is the constant ratio between any two successive spindle speeds. It is the most important design
parameter in a machine tool gear box. Write 4 points for 4 marks, 6 points for 6 marks.
• Uniform machining efficiency: Since percentage speed drop between any two consecutive steps
equals (phi - 1) x 100%, the percentage loss of economic cutting speed is the same at every speed
level. The machine works at the same efficiency at all speeds.
• Controls number of speeds: A smaller phi gives more speed steps (finer resolution) but needs
more gears. A larger phi gives fewer steps but coarser control. phi directly decides how many steps
are needed between N_min and N_max.
• Determines gear ratios: Every gear ratio in the box is a power of phi. The same gear pair can
appear in different stages — reduces total number of unique gear pairs needed.
• Based on preferred number series: Standard phi values (1.06, 1.12, 1.25, 1.41, 1.58, 1.78, 2.0)
come from the Renard (R) series — ensures standardised, interchangeable designs.
• Links R, phi and z: The relation phi = R^(1/(z-1)) connects N_max, N_min and z. Fixing any two
determines the third.
 • Practical preferred range: phi between 1.25 and 1.58 gives the best balance between number of
speeds and machining efficiency in practice.

Key relation: phi = (N_max / N_min)^(1/(z-1))

Practical preferred: 1.25 <= phi <= 1.58

5.5 Important Parameters in Kinematic Design ★★

(i) Range Ratio R
R = N_max / N_min
Ratio of maximum to minimum spindle speed. Indicates width of speed coverage.

(ii) Progression Ratio phi

phi = (N_max / N_min)^(1/(z-1))
Constant step ratio between successive speeds. Determines step size.

(iii) Number of Spindle Speed Steps z

z = P1 x P2 x P3 x ...
Total output speeds. P1, P2 = ratios per stage. Common: 2x3=6, 3x2=6, 2x3x2=12, 3x4=12.

(iv) Number of Stages

Each pair of shafts with sliding gears = one stage. Total speeds = product of ratios per stage.

(v) Transmission Range of a Stage

Transmission range = phi^((P-1) x x)

Constraint for EVERY stage: i_max <= 2 and i_min >= 1/4
i_max = 2 means maximum speed increase per stage is 2:1.
i_min = 1/4 means maximum speed reduction per stage is 4:1.
Any gear pair violating this is physically not feasible.

5.6 Structural Formula ★★★

Definition
A structural formula represents the arrangement of gear stages in a multi-speed gear box. It shows how
many speed ratios each stage contributes and how far apart those ratios are (in phi steps).
z = P1(x1) . P2(x2) . P3(x3)
• P1, P2, P3 = number of speed ratios contributed by stage 1, 2, 3.
• x1, x2, x3 = characteristic of each stage — spacing in phi steps between the speeds of that stage.

Rule for Characteristic Values (must memorise)

 x1 = 1
x2 = P1
x3 = P1 x P2
Each stage's characteristic = product of ALL previous stages' P values.

Three Structural Formulae for a 12-Speed Gear Box ★★★

Write any 3 of these in the exam:

Structural Formula Stage 1 Stage 2 Stage 3

2(1) . 3(2) . 2(6) 2 speeds, x=1 3 speeds, x=2 2 speeds, x=6

3(1) . 2(3) . 2(6) 3 speeds, x=1 2 speeds, x=3 2 speeds, x=6

3(1) . 4(3) 3 speeds, x=1 4 speeds, x=3 —

4(1) . 3(4) 4 speeds, x=1 3 speeds, x=4 —

2(1) . 2(2) . 3(4) 2 speeds, x=1 2 speeds, x=2 3 speeds, x=4

Why All Structural Formulae Cannot Be Converted to Structure Diagrams

A structural formula is feasible ONLY if every stage satisfies i_max <= 2 and i_min >= 1/4.
Many combinations of P and x violate these transmission range constraints. For example, if x is very
large, the rays of that stage would need to span too many speed steps, making the gear ratio exceed 2:1
or go below 1:4 — which is mechanically not feasible. Such formulae exist mathematically but cannot be
built as a real gear box. This is why all structural formulae cannot be converted into structure diagrams.

5.7 Structure Diagram (Ray Diagram) ★★★

What is a Structure Diagram?

A structure diagram is a graphical method to represent all speeds and gear ratios across all shafts of
a gear box.
• X-axis: Shaft numbers — Input shaft (I), Shaft II, Shaft III, Output shaft.
• Y-axis: Speeds on logarithmic scale. Each equal division = one phi step.
• Each line (ray) connecting speeds on adjacent shafts = one gear ratio.
• Horizontal ray = 1:1 ratio (no speed change).
• Ray sloping upward = speed increase. Ray sloping downward = speed reduction.

Rules for Drawing Structure Diagram

• Mark shaft positions on x-axis. Mark z speed levels on y-axis equally spaced (each gap = 1 phi step).
• For each stage, draw P rays from each point on driving shaft, fanning out to P points on driven shaft.
• Rays in each stage must be symmetric about the horizontal ray — fan equally up and down.
• Maximum upward slope = 1 step up per stage (speed increase ratio <= 2).
• Maximum downward slope = 2 steps down per stage (speed reduction ratio >= 1/4).
• Rays within the same stage must NOT cross each other.
 • Number of rays from each point on a shaft = P value of that stage.

The Four Standard 6-Speed Structural Formulae ★★★

These four come up in nearly every paper. Know all four and which is optimum.

Formula Stage 1 Stage 2 Status

2(1) . 3(2) 2 ratios, step=1 3 ratios, step=2 Feasible

Often not feasible

— step=3 with
2(3) . 3(1) 2 ratios, step=3 3 ratios, step=1
P=2 makes rays
too steep

Feasible —
3(1) . 2(3) 3 ratios, step=1 2 ratios, step=3
OPTIMUM

3(2) . 2(1) 3 ratios, step=2 2 ratios, step=1 Feasible

How to Identify the Optimum Structural Formula ★★★

• Rule 1 — Largest P first: Stage with the most speed ratios (highest P) should be Stage 1 (closest to
input). Minimises torque on gears and keeps gear sizes small.
• Rule 2 — Characteristics must increase: x2 > x1, x3 > x2 — step spacing increases from stage to
stage.
• Rule 3 — All stages must be feasible: Every stage must satisfy i_max <= 2 and i_min >= 1/4 for all
its rays.
• Rule 4 — Minimum spread: Stage should use smallest possible transmission range — rays fan out
as little as possible.

For the standard 4 formulae of a 6-speed box:

OPTIMUM = 3(1) . 2(3)
Reason: Largest group (P=3) is in Stage 1. Characteristics increase (1 then 3). All gear ratios within
feasible limits.

Gearing Diagram (Schematic Layout / Kinematic Diagram)

After identifying the optimum structural formula, draw the gearing diagram showing the physical
arrangement of shafts and gears.
• Draw all shafts as parallel horizontal lines, one below the other.
• Show each meshing gear pair as two interlocking circles.
• A stage with P ratios between two shafts has P gear pairs — one for each speed ratio.
• Gears that slide on a shaft to engage different pairs = gear cluster (shown as a block that moves left
or right).
• Label number of teeth on each gear after calculating.
• Input shaft connects to motor (directly or via belt and pulleys).

5.8 Reading a Given Structure Diagram ★★

When a structure diagram is given in the exam, extract the following in order:
 • Step 1: Count speed levels at output shaft = z.
• Step 2 — Write structural formula: For each stage, count rays from one point on driving shaft = P.
Count phi steps between where rays land on driven shaft = x. Write P1(x1) . P2(x2).
• Step 3 — Find phi: phi = N2/N1 from the two smallest consecutive output speeds. OR: phi =
(N_max/N_min)^(1/(z-1)).
• Step 4 — Find R: R = N_max / N_min.
• Step 5 — Find input shaft speed: Trace the horizontal (1:1) ray backward from output through all
stages to input.
• Step 6 — Find gear ratios: For each ray, i = (speed on driven shaft) / (speed on driving shaft).
• Step 7 — Calculate teeth: Assume T_min = 20. Use T1 + T2 = S (constant per shaft pair). S = 20 x
(1 + i_max). For each pair: T1 = S/(1+i), T2 = S - T1.

Centre distance rule: T1 + T2 = S (same for ALL gear pairs between same two shafts)
Finding S: S = 20 x (1 + i_max) using the pair with highest ratio on those two shafts.
Each pair: T1 = S / (1 + i) T2 = S - T1

5.9 Procedure for Kinematic Design of Multi-Speed Gear Box ★★

Steps to design a gear box from scratch. Knowing this earns marks for 'Write the procedure for kinematic
design.'
• Step 1: Note given data — N_min, N_max, z, motor speed N_m.
• Step 2: Find phi = (N_max/N_min)^(1/(z-1)). Round to nearest standard value.
• Step 3: Find all z spindle speeds: N1=N_min, N2=N1 x phi, N3=N1 x phi^2, ... Round each to
nearest standard speed.
• Step 4: Choose structural formula. Select P1, P2 so P1 x P2 = z. Apply optimum rules.
• Step 5: Draw structure diagram. Verify all rays satisfy i_max <= 2 and i_min >= 1/4.
• Step 6: Draw speed diagram — label actual speed values on y-axis.
• Step 7: Find gear ratios for each ray in each stage.
• Step 8: Calculate number of teeth — T_min=20, T1+T2=constant per shaft pair.
• Step 9: If belt drive to motor — find pulley ratio = N_input/N_motor. Select from R20 standard series.

5.10 Laws for Stepped Regulation of Speeds ★★★

Question: 'What are the various laws for stepped regulation of speeds in multi-speed gear boxes? State
advantages and disadvantages.'
Present all three laws. Use the detailed content from section 5.3 and the comparison table. Quick
summary:
• AP: Speeds differ by constant absolute value. Simple but unequal cutting speed loss — not
preferred.
• GP: Speeds differ by constant ratio phi. Equal percentage loss of cutting speed — most preferred,
universally used.
• HP: Reciprocals of speeds are in AP. Closer spacing at low rpm — rarely used, unequal cutting
speed loss.
Then present the comparison table from section 5.3 and full advantages/disadvantages of each law.
5.11 Important Terms — Quick Reference

Term Meaning

Range ratio R R = N_max/N_min — ratio of highest to lowest spindle speed.

Transmission range Same as range ratio — the spread of speeds available.

Progression ratio phi Constant ratio between successive speeds in a GP series.

Structural formula P1(x1).P2(x2) — represents how stages are arranged.

Characteristic x Spacing in phi steps between speeds within one stage.

Structure diagram Graph of speeds vs shaft positions; rays = gear ratios.

Ray One line in the structure diagram = one gear ratio between two shafts.

Gearing diagram Schematic showing physical shaft and gear pair arrangement.

i_max Maximum gear ratio per stage = 2 (speed increase limit).

i_min Minimum gear ratio per stage = 1/4 (speed reduction limit).

Optimum formula Structural formula with largest P first and increasing characteristics.

z Total number of output spindle speeds.

Economic cutting speed Ideal cutting speed for given tool, material and job diameter.

Loss of cutting speed Gap between ideal and nearest available spindle speed.

Formula Sheet — Everything at a Glance

What Formula

Progression ratio phi = (N_max / N_min)^(1 / (z-1))

Range ratio R = N_max / N_min = phi^(z-1)

Speed at step n N_n = N_min x phi^(n-1)

Structural formula z = P1(x1) . P2(x2) . P3(x3)

Characteristic rule x1=1, x2=P1, x3=P1 x P2

Feasibility per stage i_max <= 2 and i_min >= 1/4

Centre distance condition T1 + T2 = constant (same for all pairs on same shaft pair)

Teeth from ratio T1 = S/(1+i), T2 = S - T1

Pulley ratio D_motor / D_gearbox = N_input / N_motor

 Largest P in first stage, characteristics increasing
Optimum formula rule
stage-by-stage

Exam Strategy Summary

Topic Papers Marks Priority

Structure diagrams for all 4 formulae +

5 of 6 6-8 ★★★
identify optimum + gearing diagram

Structural formula — definition + 3 formulae

4 of 6 4-6 ★★★
for 12-speed

AP vs GP vs HP — laws / differentiate /
5 of 6 4-6 ★★★
adv. and disadv.

Significance of phi (GP ratio) 3 of 6 4-6 ★★★

Basic considerations in gear box design 2 of 6 4-6 ★★

Read given structure diagram — phi, R,

2 of 6 8-10 ★★
formula, layout, teeth

Kinematic parameters (R, phi, z, stages,

2 of 6 4 ★★
transmission range)

Procedure for kinematic design (steps) 1 of 6 6 ★

★ Most important skill for full marks in Unit 5:

Know all 4 structural formulae. Know which is optimum (3(1).2(3)) and WHY (3 rules).
Be able to draw all 4 structure diagrams without hesitation.
Second most important: GP — significance of phi, formula, advantages over AP and HP.
These two topics alone cover 50-60% of all Q5/Q6 marks across all 6 papers.