Chapter 5 : Design of Multi-Speed Gear Boxes

Section 5.15 :

Example 5.3 :
Find the speed steps arranged in geometric progression for the following condition :
Nmin = 100 r.p.m., Nmax = 1800 r.p.m., z = 8.
Also draw the best possible structure diagram for the same.
Solution :
Given : min = 100 r.p.m.; max = 1800 r.p.m ; z = 8.
1. Range ratio (Rn) :
nmax 1800
Rn = n = 100 = 18
min

2. Geometric progression ratio () :

1 1
 = (z  1) = (8  1) or  = 1.5112
Rn (18)
3. Spindle speeds (nk) :
The spindle speeds are given in Table 5.3.1
Table 5.3.1 : Simple Speeds

Speeds Steps Spindle Speed, ‘nk’ r.p.m.

Expression Speed
1 n1 = nmin n1 = 100
2 n2 = n1  = 100  1.5112 n2 = 151
2 2
3 n3 = n1  = 100  (1.5112) n3 = 228.5
3 3
4 n4 = n1  = 100  (1.5112) n4 = 345
4 4
5 n5 = n1  = 100  (1.5112) n5 = 521.5
5 5
6 n6 = n1  = 100  (1.5112) n6 = 788
6 6
7 n7 = n1  = 100  (1.5112) n7 = 1191
7 7
8 n8 = n1  = 100  (1.5112) n8 = 1800
 Machine Design - II (GTU) 5-2 Design of Multi-speed Gear Boxes

4. Number of stages of gear box (N) :

log10 z
N = log P
10

Assuming P = 2;
log10 8
N = log 2
10

or N = 3
5. Structural formulae :
 The three stage gear box is selected with each stage of two-speed steps (p = 2).
 z = 222
 The structural formulae for gear box is given by,
z = p1 (x1) p2 (x2) p3 (x3)
or z = 2 (x1) 2 (x2) 2 (x3) …(a)
 The values of x1, x2 and x3 are obtained as follows :
(i) x1 = 1
(ii) x2 = value of p corresponding to x1
(iii) x3 = (value of p corresponding to x1)  (value of p corresponding to x2)
 z = p1 (x1) p2 (x2) p3 (x3) = 2 (x1) 2 (x2) 2 (x3)
 p1 = 2 ; p2 = 2; p3 = 2
 x1 = 1; x2 = p1 = 2; x3 = p1 p2 = 2  2 = 4
 z = 2 (1) 2 (2) 2 (4)
 By changing the positions of x1, x2 and x3 in Equation (a), the following candidate
structural formulae can be obtained.
z = 2 (1) 2 (2) 2 (4) ….(i)
z = 2 (1) 2 (4) 2 (2) …(ii)
z = 2 (2) 2 (4) 2 (1) …(iii)
z = 2 (2) 2 (1) 2 (4) …(iv)
z = 2 (4) 2 (1) 2 (2) …(v)
z = 2 (4) 2 (2) 2 (1) …(vi)
6. Structure diagrams :
The structure diagrams constructed From Equations (i) to (iv) are shown in Fig. 5.3.1.
Machine Design - II (GTU) 5-3 Design of Multi-speed Gear Boxes

Fig. 5.3.1 Contd…

Fig. 5.3.1 : Different Structure Diagrams

 Machine Design - II (GTU) 5-4 Design of Multi-speed Gear Boxes

7. Optimum (best possible ) structure diagram :

The node method of optimization is used for determining the optimum structure diagram
(Table 5.3.2).
Table 5.3.2 : Node Method of Optimization

Structure Nodes on Transmission Line  Node Remark

Diagram Number
Shaft-I Shaft-II Shaft-III Shaft-IV

Fig. 5.3.1(i) 4.5 5 6 8 23.5 Optimum

Fig. 5.3.1(ii) 4.5 5 7 8 24.5

Fig. 5.3.1(iii) 4.5 5.5 7.5 8 25.5

Fig. 5.3.1(iv) 4.5 5.5 6 8 24

Fig. 5.3.1(v) 4.5 6.5 7 8 26

Fig. 5.3.1(vi) 4.5 6.5 7.5 8 26.5

 Hence, the structure diagram, shown in Fig. 5.3.1(i), is the optimum (best possible)
structure diagram.
 It also satisfies the condition x1  x2  x3.
Example 5.6 :
A multi-speed gear box is to be designed for a medium-size, general-purpose machine tool for
spindle speeds varying between 20 r.p.m. and 894 r.p.m. If the recommended geometric
progression ratio is as per R 20/3 series :
(i) Draw the candidate structure diagrams for machine tool gear box ; and
(ii) Select the optimum structure diagram.
If the gear box is driven by 750 r.p.m., three phase A.C. motor through a belt drive, draw the
optimum speed diagram and determine the speed of input shaft.
Solution :
nmin = 20 r.p.m. ; nmax = 894 r.p.m ;
 = R 20/3.
1. Geometric progression ratio () :
20/3
 = 10

or  = 1.4125
 Machine Design - II (GTU) 5-5 Design of Multi-speed Gear Boxes

2. Range ratio (Rn) :

nmax 894
Rn = n = 20
min

or Rn = 44.7
3. Number of speed steps (z) :
log10 (Rn ) log10 (44.7  1.4125)
z = = = 12.003
log10  log10 1.4125
or z = 12
4. Spindle speeds (nk) :
The spindle speeds are given in Table 5.6.1.
Table 5.6.1 : Spindle Speeds

Speed Step Spindle Speed, ‘nk’ r.p.m.

Expression Speed
1 n1 = nmin n1 = 20

2 n2 = n1  = 20  1.4125 n2 = 28
2 2
3 n3 = n1  = 20  (1.4125) n3 = 40
3 3
4 n4 = n1  = 20  (1.4125) n4 = 56.5
4 4
5 n5 = n1  = 20  (1.4125) n5 = 80
5 5
6 n6 = n1  = 20  (1.4125) n6 = 112.5
6 6
7 n7 = n1  = 20  (1.4125) n7 = 159
7 7
8 n8 = n1  = 20  (1.4125) n8 = 224.5
8 8
9 n9 = n1  = 20  (1.4125) n9 = 317
9 9
10 n10 = n1  = 20  (1.4125) n10 = 448
10 10
11 n11 = n1  = 20  (1.4125) n11 = 632.5
11 11
12 n12 = n1  = 20  (1.4125) n12 = 894

5. Number of stages of gear box (N) :

log10 z
N = log p
10
 Machine Design - II (GTU) 5-6 Design of Multi-speed Gear Boxes

log10 12
Assuming p = 2; N = log 2 = 3.58
10

log10 12
Assuming p = 3; N = log 3 = 2.26
10

 As N = 3.58 and N = 2.26 are not integer numbers, it is not possible to take all
stages of gear box of two-speed steps (p = 2) or three-speed steps (p = 3).
 Therefore,
N N
z = 2 13 2
2 1
12 = 2  3
 N1 = 2 and N2 = 1
 N = N1 + N2 = 2 + 1
or N = 3
 Hence, three stage gear box is selected with two stages of two speed steps(p = 2)
and one stage of three-speed step (p = 3).
 z = 223
6. Structural formulae :

 The structural formulae for gear box is given by,

z = p1 (x1) p2 (x2) p3 (x3)
or z = 2 (x1) 2 (x2) 3 (x3) …(a)
 By changing the positions of P1, P2 and P3 , the following set of structural formulae
can be obtained :
z = 2 (x1) 2 (x2) 3 (x3)
z = 3 (x1) 2 (x2) 2 (x3) …(b)
z = 2 (x1) 3 (x2) 2 (x3)
 The values of x1, x2 and x3 are obtained as follows :
(i) x1 = 1
(ii) x2 = value of p corresponding to x1
(iii) x3 = (value of p corresponding to x1)  (value of p corresponding to x2)
 By changing the positions of x1, x2 and x3 in Equation (b), following nine candidate
structural formulae (three sets) can be obtained.
SET ONE :
z = p1 (x1) p2 (x2) p3 (x3) = 2 (x1) 2 (x2) 3 (x3)
 p1 = 2; p2 = 2; p3 = 3
 Machine Design - II (GTU) 5-7 Design of Multi-speed Gear Boxes

 z = 2 (x1) 2 (x2) 3 (x3); x1 = 1, x2 = p1 = 2, x3 = p1 p2 = 2  2 = 4

or z = 2 (1) 2 (2) 3 (4) …(i)

 z = 2 (x3) 2 (x1) 3 (x2); x1 = 1, x2 = p2 = 2; x3 = p2 p3 = 2  3 = 6

or z = 2 (6) 2 (1) 3 (2) …(ii)

 z = 2 (x2) 2 (x3) 3 (x1); x1 = 1 x2 = p3 = 3, x3 = p3 p1 = 3  2 = 6

or z = 2 (3) 2 (6) 3 (1) …(iii)

SET TWO :
z = p1 (x1) p2 (x2) p3 (x3) = 3 (x1) 2 (x2) 2 (x3)
 p1 = 3; p2 = 2; p3 = 2
 z = 3 (x1) 2 (x2) 2 (x3); x1 = 1; x2 = p1 = 3; x3 = p1 p2 = 3  2 = 6

or z = 3 (1) 2 (3) 2 (6) …(iv)

 z = 3 (x3) 2 (x1) 2 (x2); x1 = 1; x2 = p2 = 2; x3 = p1 p2 = 2  2 = 4
or z = 3 (4) 2 (1) 2 (2) …(v)
 z = 3 (x2) 2 (x3) 2 (x1); x1 = 1; x2 = p3 = 2; x3 = p3 p1 = 2  3 = 6

or z = 3 (2) 2 (6) 2 (1) …(vi)

SET THREE
z = p1 (x1) p2 (x2) p3 (x3) = 2 (x1) 3 (x2) 2 (x3)
p1 = 2; p2 = 3; p3 = 2
 z = 2 (x1) 3 (x2) 2 (x3); x1 = 1; x2 = p1 = 2, x3 = p1 p2 = 2  3 = 6

or z = 2 (1) 3 (2) 2 (6) …(vii)

 z = 2 (x3) 3 (x1) 2 (x2); x1 = 1, x2 = p2 = 3, x3 = p2 p3 = 3  2 = 6

or z = 2 (6) 3 (1) 2 (3) …(viii)

 z = 2 (x2) 3 (x3) 2 (x1); x1 = 1; x2 = p3 = 2; x3 = p3 p1 = 2  2 = 4
or z = 2 (2) 3 (4) 2 (1) …(ix)
7. Structure Diagrams :
The structure diagrams constructed from Equations (i) to (ix) are shown in Fig. 5.6.1.
Machine Design - II (GTU) 5-8 Design of Multi-speed Gear Boxes

Fig. 5.6.1 : Continued....

Machine Design - II (GTU) 5-9 Design of Multi-speed Gear Boxes

Fig. 5.6.1 : Continued....

Machine Design - II (GTU) 5-10 Design of Multi-speed Gear Boxes

Fig. 5.6.1 : Continued....

Machine Design - II (GTU) 5-11 Design of Multi-speed Gear Boxes

Fig. 5.6.1 : Continued....

 Machine Design - II (GTU) 5-12 Design of Multi-speed Gear Boxes

Fig. 5.6.1 : Different Structure Diagrams

8. Optimum structure diagram :
 The node method of optimization is used for determining optimum structure
diagram (Table 5.6.2).
Table 5.6.2 : Node Method of Optimization

Structure (ig)stage < 8 Feasibility Nodes on Transmission Line ∑ (Node Remark

Diagram Number)
Shaft- Shaft- Shaft- Shaft-
I II III IV
5.6.1(i) No Not 6.5 7 10 12 3.5
Feasible
5.6.1(ii) Yes Feasible 6.5 9.5 10 12 38.0
5.6.1(iii) Yes Feasible 6.5 8 11 12 37.5
5.6.1(iv) Yes Feasible 6.5 7.5 9 12 35.0
5.6.1(v) No Not 6.5 10.5 11 12 40.0
Feasible
 Machine Design - II (GTU) 5-13 Design of Multi-speed Gear Boxes

Structure (ig)stage < 8 Feasibility Nodes on Transmission Line ∑ (Node Remark

Diagram Number)
Shaft- Shaft- Shaft- Shaft-
I II III IV
5.6.1(vi) Yes Feasible 6.5 8.5 11 12 38.0
5.6.1(vii) Yes Feasible 6.5 7 9 12 34.5 Optimum
Diagram
5.6.1(viii) Yes Feasible 6.5 9.5 10.5 12 38.5
5.6.1(ix) No Not 6.5 7.5 11.5 12 37.5
Feasible
 Hence the structure diagram, shown in Fig. 5.6.1(vii), is the optimum structure
diagram.
 It also satisfies the condition x1 < x2 < x3.
9. Optimum speed ray diagram :
Fig. 5.6.2 shows the optimum speed ray diagram.

Fig. 5.6.2 : Optimum Speed Diagram

 Machine Design - II (GTU) 5-14 Design of Multi-speed Gear Boxes

10. Speed of Input Shaft (ni) :

From Fig. 5.6.2,
log10 
log10 ni = log10 n6 + 2
log10 (1.4125)
= log10 (112.5) + 2
or log10 ni = 2.1261
 ni = 133.7 r.p.m. ...Ans.
11. Kinematic (gearing) diagram of gear box :
Kinematic (gearing) diagram of gear box is shown in Fig. 5.6.3.

Fig. 5.6.3 : Kinematic (Gearing) Diagram of Gear Box

Example 5.7 :
A multi-speed, sliding mesh gear box is to be designed for a tapping spindle speeds varying
between 20 r.p.m. and 3170 r.p.m. The recommended geometric progression ratio is as per
R5 series. The gear box is driven by 720 r.p.m. Three phase A.C. motor through a belt drive.
(i) draw the candidate structure diagrams for machine tool gear box ;
(ii) select the optimum structure diagram.
(iii) draw the optimum speed ray diagram; and
(iv) draw the gearing diagram when third speed form the bottom is tapped.
 Machine Design - II (GTU) 5-15 Design of Multi-speed Gear Boxes

Solution :
nmin = 20 r.p.m. ; nmax = 3170 r.p.m ;
 = R5.
1. Geometric progression ratio () :
5
 = 10
or  = 1.5849
2. Range ratio (Rn) :
nmax 3170
Rn = n = 20
min

or Rn = 158.5
3. Number of speed steps (z) :
log10 (Rn ) log10 (158.5  1.5849)
z = = = 12.00
log10  log10 1.5849
or z = 12
4. Spindle speeds (nk) :
The spindle speeds are given in Table 5.7.1.
Table 5.7.1 : Spindle Speeds

Speed Step Spindle Speed, ‘nk’ r.p.m.

Expression Speed
1 n1 = nmin n1 = 20
2 n2 = n1  = 20  1.5849 n2 = 31.5
2 2
3 n3 = n1  = 20  (1.5849) n3 = 50
3 3
4 n4 = n1  = 20  (1.5849) n4 = 79.5
4 4
5 n5 = n1  = 20  (1.5849) n5 = 126
5 5
6 n6 = n1  = 20  (1.5849) n6 = 200
6 6
7 n7 = n1  = 20  (1.5849) n7 = 317
7 7
8 n8 = n1  = 20  (1.5849) n8 = 502.5
8 8
9 n9 = n1  = 20  (1.5849) n9 = 796
9 9
10 n10 = n1  = 20  (1.5849) n10 = 1262
10 10
11 n11 = n1  = 20  (1.5849) n11 = 2000
11 11
12 n12 = n1  = 20  (1.5849) n12 = 3170
 Machine Design - II (GTU) 5-16 Design of Multi-speed Gear Boxes

5. Number of stages of gear box (N) :

log10 z
N = log p
10

log10 12
Assuming p = 2; N = log 2 = 3.58
10

log10 12
Assuming p = 3; N = log 3 = 2.26
10

 As N = 3.58 and N = 2.26 are not integer numbers, it is not possible to take all
stages of gear box of two-speed steps (p = 2) or three-speed steps (p = 3).
 Therefore,
N N
z = 2 13 2
2 1
12 = 2  3

 N1 = 2 and N2 = 1

 N = N1 + N2 = 2 + 1

or N = 3

 Hence, three stage gear box is selected with two stages of two speed steps(p = 2)
and one stage of three-speed step (p = 3).

 z = 223
6. Structural formulae :
 The structural formulae for gear box is given by,

z = p1 (x1) p2 (x2) p3 (x3)

or z = 2 (x1) 2 (x2) 3 (x3) …(a)

 By changing the positions of p1, p2 and p3 , the following set of structural formulae
can be obtained :
z = 2 (x1) 2 (x2) 3 (x3)

z = 3 (x1) 2 (x2) 2 (x3) …(b)

z = 2 (x1) 3 (x2) 2 (x3)

 Machine Design - II (GTU) 5-17 Design of Multi-speed Gear Boxes

 The values of x1, x2 and x3 are obtained as follows :

(i) x1 = 1
(ii) x2 = value of p corresponding to x1
(iii) x3 = value of p corresponding to x1  value of p corresponding to x2
 By changing the positions of x1, x2 and x3 in Equation (b), following nine candidate
structural formulae (three sets) can be obtained.
SET ONE :
z = p1 (x1) p2 (x2) p3 (x3) = 2 (x1) 2 (x2) 3 (x3)
 p1 = 2; p2 = 2; p3 = 3
 z = 2 (x1) 2 (x2) 3 (x3); x1 = 1, x2 = p1 = 2, x3 = p1 p2 = 2  2 = 4

or z = 2 (1) 2 (2) 3 (4) …(i)

 z = 2 (x3) 2 (x1) 3 (x2); x1 = 1, x2 = p2 = 2; x3 = p2 p3 = 2  3 = 6

or z = 2 (6) 2 (1) 3 (2) …(ii)

 z = 2 (x2) 2 (x3) 3 (x1); x1 = 1 x2 = p3 = 3, x3 = p3 p1 = 3  2 = 6

or z = 2 (3) 2 (6) 3 (1) …(iii)

SET TWO :
z = p1 (x1) p2 (x2) p3 (x3) = 3 (x1) 2 (x2) 2 (x3)
 p1 = 3; p2 = 2; p3 = 2
 z = 3 (x1) 2 (x2) 2 (x3); x1 = 1; x2 = p1 = 3; x3 = p1 p2 = 3  2 = 6

or z = 3 (1) 2 (3) 2 (6) …(iv)

 z = 3 (x3) 2 (x1) 2 (x2); x1 = 1; x2 = p2 = 2; x3 = p1 p2 = 2  2 = 4

or z = 3 (4) 2 (1) 2 (2) …(v)

 z = 3 (x2) 2 (x3) 2 (x1); x1 = 1; x2 = p3 = 2; x3 = p3 p1 = 2  3 = 6

or z = 3 (2) 2 (6) 2 (1) …(vi)

SET THREE
z = p1 (x1) p2 (x2) p3 (x3) = 2 (x1) 3 (x2) 2 (x3)
p1 = 2; p2 = 3; p3 = 2
 z = 2 (x1) 3 (x2) 2 (x3); x1 = 1; x2 = p1 = 2, x3 = p1 p2 = 2  3 = 6
or z = 2 (1) 3 (2) 2 (6) …(vii)
 z = 2 (x3) 3 (x1) 2 (x2); x1 = 1, x2 = p2 = 3, x3 = p2 p3 = 3  2 = 6
 Machine Design - II (GTU) 5-18 Design of Multi-speed Gear Boxes

or z = 2 (6) 3 (1) 2 (3) …(viii)

 z = 2 (x2) 3 (x3) 2 (x1); x1 = 1; x2 = p3 = 2; x3 = p3 p1 = 2  2 = 4
or z = 2 (2) 3 (4) 2 (1) …(ix)
7. Structure diagrams :
The structure diagrams constructed from Equations (i) to (ix) are shown in Fig. 5.7.1.

Fig. 5.7.1 : Continued....

Machine Design - II (GTU) 5-19 Design of Multi-speed Gear Boxes

Fig. 5.7.1 : Continued....

Machine Design - II (GTU) 5-20 Design of Multi-speed Gear Boxes

Fig. 5.7.1 : Continued....

Machine Design - II (GTU) 5-21 Design of Multi-speed Gear Boxes

Fig. 5.7.1 : Continued....

 Machine Design - II (GTU) 5-22 Design of Multi-speed Gear Boxes

Fig. 5.7.1 : Different Structure Diagrams

Note : None of the structure diagram is satisfying the condition of transmission range
i.e. (ig)stage  8. Therefore this condition is exempted in design procedure.

8. Optimum structure diagram :

 The node method of optimization is used for determining optimum structure

diagram (Table 5.7.2).
Table 5.7.2 : Node Method of Optimization

Structure Nodes on Transmission Line ∑ (Node Remark

Diagram Number)
Shaft-I Shaft-II Shaft-III Shaft-IV
5.7.1(i) 6.5 7 10 12 3.5
5.7.1(ii) 6.5 9.5 10 12 38.0
5.7.1(iii) 6.5 8 11 12 37.5
5.7.1(iv) 6.5 7.5 9 12 35.0
 Machine Design - II (GTU) 5-23 Design of Multi-speed Gear Boxes

Structure Nodes on Transmission Line ∑ (Node Remark

Diagram Number)
Shaft-I Shaft-II Shaft-III Shaft-IV
5.7.1(v) 6.5 10.5 11 12 40.0
5.7.1(vi) 6.5 8.5 11 12 38.0
5.7.1(vii) 6.5 7 9 12 34.5 Optimum
Diagram
5.7.1(viii) 6.5 9.5 10.5 12 38.5
5.7.1(ix) 6.5 7.5 11.5 12 37.5

 Hence the structure diagram, shown in Fig. 5.7.1(vii), is the optimum structure
diagram.
 It also satisfies the condition x1 < x2 < x3.
9. Optimum speed diagram :
Fig. 5.7.2 shows the optimum speed diagram.

Fig. 5.7.2 : Optimum Speed Diagram

 Machine Design - II (GTU) 5-24 Design of Multi-speed Gear Boxes

10. Speed of input shaft (ni) :

From Fig. 5.7.2,
log10 
log10 ni = log10 n6 + 2
log10 (1.5849)
= log10 (200) + 2
or log10 ni = 2.401
 ni = 251.8 r.p.m. ..Ans.
11. Ray diagram :
Fig. 5.7.3 shows the ray diagram when the third speed from the bottom is being tapped.

Fig. 5.7.3 : Ray Diagram

 Machine Design - II (GTU) 5-25 Design of Multi-speed Gear Boxes

12. Kinematic (gearing) diagram of gear box :

Kinematic (gearing) diagram of gear box is shown in Fig. 5.7.4.

Fig. 5.7.4 : Kinematic (Gearing) Diagram of Gear Box When Speed of 50 r.p.m. is Being Tapped

Example 5.8 :
A multi speed gear box is to be designed for a headstock of a turret lathe for nine spindle
speeds ranging from 30 r.p.m. to 1000 r.p.m. If the gear box is driven by 5 kW, 720 r.p.m.
electric motor through the belt drive :
(i) draw the speed ray diagram ;
(ii) draw the gearing diagram;
(iii) determine the number of teeth on gears ;
(iv) select the diameters of pulleys for belt drive ; and
(v) draw the deviation diagram.
The standard pulley diameters are : 80, 90, 100, 112, 125, 140, 160, 180, 200, 224, 250, 280,
290, 300, 310, 355, 375, 400, 450, 500 mm
Assume same module for all gears.
Solution :
Given : z =9 ; nmin = 30 r.p.m. ;
nmax = 1000 r.p.m. ; P = 5 kW;
nem = 720 r.p.m.
 Machine Design - II (GTU) 5-26 Design of Multi-speed Gear Boxes

1. Range ratio (Rn) :

nmax 1000
Rn = n = 30 = 33.33
min

2. Geometric progression ratio () :

1 1
(z – 1) (9 – 1)
 = Rn = (33.33)

or  = 1.55
3. Spindle speeds (nk) :
The spindle speeds are given in Table 5.8.1
Table 5.8.1 : Spindle Speeds

Speed Steps Spindle Speed, ‘nk’ r. p. m.

Expression Speed
1 n1 = nmin n1 = 30
2 n2 = n1  = 30  1.55 n2 = 46.5
2 2
3 n3 = n1  = 30  (1.55) n3 = 72
3 3
4 n4 = n1  = 30  (1.55) n4 = 112
4 4
5 n5 = n1  = 30  (1.55) n5 = 173
5 5
6 n6 = n1  = 30  (1.55) n6 = 268.5
6 6
7 n7 = n1  = 30  (1.55) n7 = 416
7 7
8 n8 = n1  = 30  (1.55) n8 = 645
8 8
9 n9 = n1  = 30  (1.55) n9 = 1000

4. Number of stages of gear box :

log10 z
 N = log p
10

log10 9
Assuming p = 2 ; N = log 2 = 3.17 (not possible)
10

log10 9
Assuming p = 3 ; N = log 3 = 2
10

 N = 2
 Machine Design - II (GTU) 5-27 Design of Multi-speed Gear Boxes

 Hence, two-stage gear box is selected with each stage of three- speed steps (p = 3).
 z = 33
5. Structural formulae :
 The structural formula for gear box is given by,
z = p1 (x1) p2 (x2)

z = 3 (1) 3 (3)
 By changing the positions of x1 and x2, the following two structural formulae can
be obtained :

z = 3(1) 3(3) …(a)

z = 3 (3) 3 (1) …(b)
 For structural formula (a); x1 < x2 hence it is feasible.

 For structural formula (b); x1 > x2 hence it is not feasible.

6. Speed ray diagram :

Fig. 5.8.1 shows the speed diagram of gear box for structural formula,

z = 3 (1) 3 (3)

Fig. 5.8.1 : Speed Ray Diagram

 Machine Design - II (GTU) 5-28 Design of Multi-speed Gear Boxes

7. Kinematic (gearing) diagram of gear box :

Kinematic (gearing) diagram of gear box is shown in Fig. 5.8.2.

Fig. 5.8.2 : Kinematic (Gearing) Diagram of Gear Box

8. Diameters of belt pulleys :

Let, ni = speed of input shaft, r.p.m.
nem = speed of electric motor shaft, r.p.m.
Di = diameter of belt pulley on input shaft, mm
Dem = diameter of belt pulley on electric motor shaft, mm
nem Di
ni = Dem
720 Di
268.5 = Dem
Di
 Dem = 2.681
 Di = 2.681 Dem
If Dem = 80 mm; Di = 214.48 mm or 215 mm [standard pulley not available]
Dem = 90 mm; Di = 241.3 mm or 241 mm [standard pulley not available]
Dem = 100 mm; Di = 268.1 mm or 268 mm [standard pulley not available]
Dem = 112 mm; Di = 300.2 mm or 300 mm [standard pulley is available]
 Machine Design - II (GTU) 5-29 Design of Multi-speed Gear Boxes

Hence, Dem = 112 mm

and Di = 300 mm ...Ans.
9. Number of teeth on gears :

Fig. 5.8.3 : Number of Teeth on Gears

(b) Actual Transmission Ratio

Fig. 5.8.3 : Number of Teeth on Gears

From Fig. 5.8.3(a) ;

(i) For first stage :
Z1i 112
Z1o = 268.5 = 0.41713

 Z1o = 2.397 Z1i …(c)

 Machine Design - II (GTU) 5-30 Design of Multi-speed Gear Boxes

Z3i 173
Z3o = 268.5 = 0.6443

 Z3o = 1.552 Z3i …(d)

Z2i 268.5
Z2o = 268.5 = 1

 Z2i = Z2o …(e)

 As centre distance as well as module are same ;
Z1i + Z1o = Z3i + Z3o = Z2i + Z2o
Z1i + Z1o = Z3i + Z3o = 2 Z2i …(f)

 As 2 Z2i has to be even number, (Z1i + Z1o) or (Z3i + Z3o) has to be even number.
 From Equations (c), (d), (e) and (f),
Z1i + 2.397 Z1i = Z3i + 1.552 Z3i = 2 Z2i

3.397 Z1i = 2.552 Z3i = 2 Z2i …(g)

 Z3i = 1.3311 Z1i …(h)

 From Equation (h) it is seen that Z1i is smallest. Hence, number of teeth on all other
gears have to be written in terms of Z1i

Z1o = 2.397 Z1i

Z3i = 1.3311 Z1i

Z3o = 1.552 Z3i = 1.552  1.3311 Z1i = 2.065 Z1i

 Number of teeth in first stage gears are estimated in Table 5.8.2.

Table 5.8.2 : Number of Teeth in First Stage Gears

Assumed Z1o Z1i + Z1o Z3i Z3o Z3i + Z3o Z2i = Z2o = Remark
Z1i = 2.397 Z1i =1.3311 Z1i = 2.065 Z1i Z3i + Z3o
2

18 43.14  43 61 23.95  24 37.17  37 61 30.5 Not

Feasible

19 45.54  46 65 25.29  25 39.23  40 65 32.5 Not

Feasible

20 47.94  48 68 26.62  27 41.3  41 68 34 Feasible

 Machine Design - II (GTU) 5-31 Design of Multi-speed Gear Boxes

 Z1i = 20 ; Z1o = 48;

Z2i = 34 ; Z2o = 34;
Z3i = 27 ; Z3o = 41 …Ans.
(ii) For second stage :
Z4i 1000
Z4o = 268.5 = 3.724

 Z4i = 3.724 Z4o …(i)

Z5i 72
Z5o = 268.5 = 0.2681

 Z5o = 3.729 Z5i …(j)

Z6i 268.5
Z6o = 268.5 = 1

 Z6i = Z6o …(k)

 Now, Z4i + Z4o = Z5i + Z5o = Z6i + Z6o

3.724 Z4o + Z4o = Z5i + 3.729 Z5i = 2 Z6i

4.724 Z4o = 4.729 Z5i = 2 Z6i
 Z4o = Z5i = 0.423 Z6i
 Number of teeth in second stage gears is estimated in Table 5.8.3.
Table 5.8.3 : Number of Teeth in Second Stage Gears

Assumed Z4i Z4i + Z4o Z5i Z5o Z5i + Z5o Z6i = Z6o Remark
Z4o = 3.724 Z4o = 3.729 Z5i Z5i + Z5o
= 2
18 67.03  67 85 18 67.17  67 85 42.5 Not
Feasible
19 70.75  71 90 19 70.85  71 90 45 Feasible

 Z4i = 71 ; Z4o = 19;

Z5i = 19 ; Z5o = 71;
Z6i = 45 ; Z6o = 45. …Ans.
10. Deviation diagram :
 The actual spindle speeds are calculated using Fig. 5.8.3(b).
nact – nth
Percentage speed deviation = n  100
th
Machine Design - II (GTU) 5-32 Design of Multi-speed Gear Boxes

 Permissible speed deviation =  10 ( – 1) =  10  (1.55 – 1) =  5.5

 The percentage speed derivations are given in Table 5.8.4.
Table 5.8.4 : Percentage Speed Derivations

Speed Step Spindle Speed, r.p.m. % Speed Permissible %

Deviation Speed Deviation
Calculated, nth Actual, nact
1 30 30.01 + 0.033  5.5
2 46.5 47.45 + 2.04  5.5
3 72 72.03 + 0.042  5.5
4 112 112 + 0.00  5.5
5 173 177 + 2.31  5.5
6 268.5 268.8 + 0.11  5.5
7 416 418.57 + 0.62  5.5
8 645 661.46 + 2.55  5.5
9 1000 1004.5 + 0.45  5.5
 Fig. 5.8.4 shows the deviation diagram.

Fig. 5.8.4 : Deviation Diagram

 Machine Design - II (GTU) 5-33 Design of Multi-speed Gear Boxes

Example 5.14 :
Fig. 5.14.1 shows the layout of machine tool gear box. It is driven by 5 kW, 750 r.p.m. electric
motor. The maximum required spindle speed is 630 r.p.m. while the speed steps are as per R10
series.
1. Determine the number of spindle speeds that can be obtained.
2. Construct speed diagram.
3. Determine the maximum torques acting on all shafts.

Fig. 5.14.1
Solution :
Given : P = 5 kW ; nem = 750 r.p.m. ;
nmax = 630 r.p.m. ;  = R10.
1. Geometric progression ratio () :
10
 = 10
or  = 1.2589
2. Number of spindle speeds (z) :
 The following observations are made from Fig. 5.14.1 :
(i) It is three stage gear box with four shafts.
 N = 3
 Machine Design - II (GTU) 5-34 Design of Multi-speed Gear Boxes

(ii) The number of gear pairs in first stage (i.e. between shafts I and II) is two. Hence,
the number of speed steps in first stage is two.
 p1 = 2
(iii) The number of gear pairs in second stage (i.e. between shafts II and III) is three.
Hence, the number of speed steps in second stage is three.
 p2 = 3
(iv) The number of gear pairs in third stage (i.e. between shafts III and IV) is two.
Hence, the number of speed steps in third stage is two.
 p3 = 2

 Hence, z = p1  p2  p3
= 232
or z = 12 …Ans.
3. Range ratio (Rn) :
(z – 1)
Rn = 
11
= (1.2589)
or Rn = 12.589
4. Minimum spindle speed (nmin) :
nmax
Rn = n
min

630
12.589 = n
min

 nmin = 50 r.p.m.
5. Spindle speeds (nk) :
The spindle speeds are given in Table 5.14.1.
Table 5.14.1 : Spindle Speed

Speed Step Spindle Speed, ‘nk’ r.p.m.

Expression Speed

1 n1 = nmin n1 = 50

2 n2 = n1  = 50  (1.2589) n2 = 63
2 2
3 n3 = n1  = 50  (1.2589) n3 = 79.5
 Machine Design - II (GTU) 5-35 Design of Multi-speed Gear Boxes

Speed Step Spindle Speed, ‘nk’ r.p.m.

Expression Speed
3 3
4 n4 = n1  = 50  (1.2589) n4 = 100
4 4
5 n5 = n1  = 50  (1.2589) n5 = 125.5
5 5
6 n6 = n1  = 50  (1.2589) n6 = 158
6 6
7 n7 = n1  = 50  (1.2589) n7 = 200
7 7
8 n8 = n1  = 50  (1.2589) n8 = 250.5
8 8
9 n9 = n1  = 50  (1.2589) n9 = 315.5
9 9
10 n10 = n1  = 50  (1.2589) n10 = 397
10 10
11 n11 = n1  = 50  (1.2589) n11 = 500
11 11
12 n12 = n1  = 50  (1.2589) n12 = 630

7. Structural formula :
 The structural formula for the given gear box is,

z = p1 (x1) p2 (x2) p3 (x3)

or z = 2 (x1) 3 (x2) 2 (x3) …(a)

 From given layout it is not possible to know the values of x1, x2, x3.

Take x1 = 1

 x2 = p1 = 2

 x3 = p1 p2 = 2  3 = 6

 Hence, the structural formula for the gear box is,

z = 2 (1) 3 (2) 2 (6) …(b)

8. Speed diagram :
Fig. 5.14.2 shows the speed diagram constructed from structural formula,

z = 2 (1) 3 (2) 2 (6).

 Machine Design - II (GTU) 5-36 Design of Multi-speed Gear Boxes

Fig. 5.14.2 : Speed Diagram

9. Input speed (ni) :

From Fig. 5.14.2 ;

log10 
log10 ni = log10 n6 + 2
log10 1.2589
= log10 158 + 2
or log10 ni = 2.2486

 ni = 177.3 r.p.m.
10. Maximum torques acting on shafts :
The power transmitted by all the shafts is same. Hence, the torque acting on the shaft is
maximum when the speed of the shaft is minimum.
2nT
P =
60  1000
 Machine Design - II (GTU) 5-37 Design of Multi-speed Gear Boxes

P  60  1000
 T =
2n
47746.48
or T = n , N-m …(c)

(i) Motor shaft :

nem = 750 r.p.m.
47746.48
Tem = nem
47746.48
= 750

or Tem = 63.66 N-m …Ans.

(ii) Input shaft (I) :
From Fig. 5.14.2, the speed of input shaft is,

ni = 177.3 r.p.m.
47746.48
 Ti = ni
47746.48
= 177.3

or Ti = 269.3 N-m …Ans.

(iii) First intermediate shaft (II) :
From Fig. 5.14.2, the minimum speed of first intermediate shaft is,

(nII)min = n6 = 158 r.p.m.

47746.48
 (TII)max = (nII)min
47746.48
= 158

or (TII)max = 302.2 N-m …Ans.

(iv) Second intermediate shaft (III) :
From Fig. 5.14.2, the minimum speed of second intermediate shaft is,
(nIII)min = 100 r.p.m.
47746.48
 (TIII)max = (nIII)min
 Machine Design - II (GTU) 5-38 Design of Multi-speed Gear Boxes

47746.48
= 100

or (TIII)max = 477.46 N-m …Ans.

(v) Output shaft (IV) :
From Fig. 5.14.2, the minimum speed of output shaft is,

(nIV)min = 50 r.p.m.
47746.48
 (TIV)max = (nIV)min
47746.48
= 50
or (TIV)max = 954.93 N-m …Ans.

Example 5.17 :
Fig. 5.17.1 shows a layout of a multi-speed gear box, with the number of teeth on different
gears specified. The lowest output speed of the gear box should be near about 100 r.p.m. The
three phase A. C. motor ‘M’ is running at 1435 r.p.m. and is driving the input shaft through the
belt drive. If all the gears have the same module :
(i) calculate the number of teeth Z1 and Z2;
(ii) list the speeds available on the output shaft;
(iii) calculate the geometric progression ratio and range ratio of the gear box;
(iv) draw the speed diagram of the gear box;
(v) write the structural formula of the gear box;
(vi) determine the output speed for the current meshing (A - P, D - S); and
(vii) determine the output speed for the meshing B - Q, C - R.

Fig. 5.17.1
 Machine Design - II (GTU) 5-39 Design of Multi-speed Gear Boxes

Solution :
Given : nmin = 100 r.p.m. ; nem = 1435 r.p.m. ;
Di = 700 mm ; Dem = 200 mm
1. Number of teeth Z1 and Z2 :
 From Fig. 5.17.1, it is seen that the lowest output speed of the gear box is obtained
through meshing A - P, C - R.
 The lowest output speed of the gear box is given by,
Dem Z1i Z3i
nmin = nem  D  Z  Z
i 1o 3o

200 22 20
= 1435  700  50  Z
1

3221.428
100 = Z1
Z1 = 32.21 or 32
 Z1 = 32 …Ans.
 From Fig. 5.17.1, as module is same for all gears,
Z3i + Z3o = Z5i + Z50
20 + Z1 = Z2 + Z2
20 + 32 = 2 Z2
52 = 2 Z2
 Z2 = 26 …Ans.

2. Speeds available on output shaft :

 From Fig. 5.17.2, it is seen that it is a two stage, six speed gear box
 Z = 23

Fig. 5.17.2
 Machine Design - II (GTU) 5-40 Design of Multi-speed Gear Boxes

 The available output speed are determined as shown in Fig. 5.17.3.

Fig. 5.17.3 : Spindle Speeds

 The spindle speeds are given in Table 5.17.1.

Table 5.17.1 : Spindle Speeds

Speed steps Calculation Spindle speed ‘nk’, r.p.m

1. n1 = 410  0.3929  0.625 n1 = 100.5
2. n2 = 410  0.3929  1 n2 = 161
3. n3 = 410  0.3929  1.6 n3 = 2575
4. n4 = 410  1.6  0.625 n4 = 410
5. n5 = 410  1.6  1 n5 = 656
6. n6 = 410  1.6  1.6 n6 = 1049.5

3. Geometric progression ratio () and range ratio (Rn) :

Geometric progression ratio
n 2 n3
 = n =n
1 2

161 257.5
= 100.5 = 161 = 1.6

or  = 1.6 …Ans.
nmax 1049.5
Range ratio, Rn = n = 100.5 = 10.44
min
 Machine Design - II (GTU) 5-41 Design of Multi-speed Gear Boxes

or Rn = 10.44 …Ans.
4. Speed diagram :
Fig. 5.17.4 shows the speed diagram.

Fig. 5.17.4 : Speed Diagram

5. Structural formula :
From Fig. 5.17.4, the structural formula for gear box can be written as,
Z = 2 (3) 3 (1) …Ans.
6. Output speed for meshing A - P, D - S :
The output speed for meshing A - P, D - S is given by,
200 22 32
nI = 1435  700  56  20 = 257.5 r.p.m.

or nI = 257.5 r.p.m. …Ans.

7. Output speed for meshing B - Q, C - R :

The output speed for meshing B - Q, C - R is given by,
200 48 20
nII = 1435  700  30  32 = 410 r.p.m.

or nII = 410 r.p.m. …Ans.

 Machine Design - II (GTU) 5-42 Design of Multi-speed Gear Boxes

Example 5.18 :
The machine tool gear box, shown in Fig. 5.18.1, is driven by 5 kW, 720 r.p.m. electric motor.
The maximum and minimum spindle speeds are 1200 r.p.m. and 30 r.p.m. respectively.
Construct the speed diagram and determine the number of spindle speeds available.

Fig. 5.18.1

Solution :
Given : P = 5 kW ; nem = 720 r.p.m. ;
nmax = 1200 r.p.m. ; nmin = 30 r.p.m.
1. Range ratio (Rn) :
nmax 1200
Rn = n = 30
min

or Rn = 40

2. Transmission from input shaft to output shaft :

From Fig. 5.18.1 it is seen that, there are two basic options in transmission of power
from input shaft ‘I’ to output shaft ‘V’ :
Option A :Clutch AA is engaged and gear pair B - B is disengaged; or
Option B : Clutch AA is disengaged and gear pair B - B is engaged.
 Machine Design - II (GTU) 5-43 Design of Multi-speed Gear Boxes

 Option A : Transmission with clutch ‘AA’ engaged and gear pair B - B disengaged :

(i) The number of gear pairs in first stage (between shafts-I and II) is two. Hence, the
number of speed steps in first stage is two.
 p1 = 2
(ii) The number of gear pairs in second stage (between shafts II and III) in two. Hence,
the number of speed steps in second stage is two.
 p2 = 2

(iii) With clutch ‘AA’ engaged and gear pair B - B disengaged, the power is
transmitted from shaft III to shaft IV and there is no direct connection between
shafts III and V.
The number of gear pairs in third stage (between shafts III and IV) is two. Hence,
the number of speed steps in third stage is two.
 p3 = 2
(iv) The number of gear pairs in fourth stage (between shafts IV and V) is two. Hence,
the number of speed steps in fourth stage is two.
 p4 = 2
(v) The number of stages for option ‘A’ is 4. The number of speed steps for option ‘A’
is,
zA = p1  p2  p3  p4 = 2  2  2  2

or zA = 16
(vi) The structural formula for option ‘A’ is,
zA = p1 (x1) p2 (x2) p3 (x3) p4 (x4)
or zA = 2 (x1) 2 (x2) 2 (x3) 2 (x4)
Now, x1 = 1
 x2 = p1 = 2
x3 = p1 p2 = 2  2 = 4
x4 = p1 p2 p3 = 2  2  2 = 8
 zA = 2 (1) 2 (2) 2 (4) 2 (8) …(a)
 Machine Design - II (GTU) 5-44 Design of Multi-speed Gear Boxes

 Option B : Transmission with clutch ‘AA’ disengaged and gear pair B - B engaged :
(i) The transmission in first two stages (i.e. up to shaft III) is same as option ‘A’
Hence, p1 = 2
and p2 = 2
(ii) Once the clutch ‘AA’ is disengaged, there is no transmission from shaft ‘III’ to
shaft ‘IV’.
(iii) The power is transmitted from shaft ‘III’ to shaft ‘V’ through a single pair of gear
B - B.
 p = 13

(iv) The number of stages for option ‘B’ is 3. The number of speed steps for option ‘B’
is,
z = p  p  p = 2  2  1
B 1 2 3
or zB = 6
(v) The structural formula for option ‘B’ is,
zB = p1 (x1) p2 (x2) p3 (x3 )
= 2 (x1) 2 (x2) 1 ( ) (x3 = 0)

or zB = 2 (1) 2 (2) 1 ( ) …(b)

3. Structural formula for gear box :
 From Equations (a) and (b) it is seen that, the arrangement is compound type.
 The structural formula for a compound speed diagram is given by,
z = zA + 2B = 2 (1) 2 (2) 2 (4) 2 (8) + 2 (1) 2 (2) 1 ( )
or z = 2 (1) 2 (2) [2 (4) 2 (8) + 1 ( ) ] …(c)
4. Number of speed steps (z) :

The number of speed steps for gear box is given by,

z = zA + aB = 16 + 4
or z = 20
5. Geometric progression ratio () :
1 1
(z – 1) (20 – 1)
 = Rn = (40)

or  = 1.2143
 Machine Design - II (GTU) 5-45 Design of Multi-speed Gear Boxes

6. Spindle speeds (nk) :

The spindle speeds are given in Table 5.18.1.

Table 5.18.1 : Spindle Speeds

Speed Spindle Speed, ‘nk’ r.p.m.

Step
Expression Speed
1 n1 = nmin n1 = 30
2 n2 = n1  = 30  (1.2143) n2 = 36.5
2 2
3 n3 = n1  = 30  (1.2143) n3 = 44
3 3
4 n4 = n1  = 30  (1.2143) n4 = 54
4 4
5 n5 = n1  = 30  (1.2143) n5 = 65
5 5
6 n6 = n1  = 30  (1.2143) n6 = 79
6 6
7 n7 = n1  = 30  (1.2143) n7 = 96
7 7
8 n8 = n1  = 30  (1.2143) n8 = 117
8 8
9 n9 = n1  = 30  (1.2143) n9 = 142
9 9
10 n10 = n1  = 30  (1.2143) n10 = 172
10 10
11 n11 = n1  = 30  (1.2143) n11 = 209
11 11
12 n12 = n1  = 30  (1.2143) n12 = 254
12 12
13 n13 = n1  = 30  (1.2143) n13 = 308.5
13 13
14 n14 = n1  = 30  (1.2143) n14 = 374.5
14 14
15 n15 = n1  = 30  (1.2143) n15 = 454.5
15 15
16 n16 = n1  = 30  (1.2143) n16 = 552
16 16
17 n17 = n1  = 30  (1.2143) n17 = 670
17 17
18 n18 = n1  = 30  (1.2143) n18 = 814
18 18
19 n19 = n1  = 30  (1.2143) n19 = 988
19 19
20 n20 = n1  = 30  (1.2143) n20 = 1200

7. Speed diagram :
 The speed diagram in this case is a compound type with option ‘A’ giving sixteen
speeds in low speed range and option ‘B’ giving four speeds in high speed range.
 This is due to the fact that in option B, the gear pair B - B is increasing the speed.
 Machine Design - II (GTU) 5-46 Design of Multi-speed Gear Boxes

 The speed diagram constructed for structural formula,

z = 2 (1) 2 (2) [2 (4) 2 (8) + 1 ( )], is shown in Fig. 5.18.2.

Fig. 5.18.2 : Speed Diagram

Example 5.19 :
The machine tool gear box, shown in Fig. 5.19.1, is driven by 10 kW, 1440 r.p.m. electric
motor. The maximum spindle speed is 1000 r.p.m. while other spindle speeds are as per R10
series. Construct the speed diagram and determine the spindle speeds available.
 Machine Design - II (GTU) 5-47 Design of Multi-speed Gear Boxes

Fig. 5.19.1

Solution :
Given : P = 10 kW ; nem = 1440 r.p.m. ;
nmax = 1000 r.p.m. ;  = R10 .
1. Geometric progression ratio () :
10
 = 10
or  = 1.2589
2. Transmission from input shaft to output shaft :
From Fig. 5.19.1 it is seen that, there are two basic options in transmission from input
shaft ‘I’ to output shaft ‘VI’ :
Option A : Clutch ‘AA’ is engaged and gear pair B - B is disengaged ; or

Option B : Clutch ‘AA’ is disengaged and pair B - B is engaged.

 Machine Design - II (GTU) 5-48 Design of Multi-speed Gear Boxes

 Option A : Transmission with clutch ‘AA’ engaged and gear pair B - B disengaged :
(i) The number of gear pairs in first stage (between shafts I and II) is three. Hence,
the number of speed steps in first stage is three.
 p1 = 3
(ii) The number of gear pairs in second stage (between shafts II and III) is two. Hence,
the number of speed steps in second stage is two.
 p2 = 2
(iii) With clutch ‘AA’ engaged and gear pair B - B disengaged, the power is
transmitted from shaft- ‘III’ through shaft ‘V’ to shaft VI without any further
change of speeds. There is no transmission through shaft ‘IV’.
(iv) The transmission from shaft ‘III’ to ‘V’ is directly through clutch.
(v) The third stage is between shafts ‘V’ and ‘VI’. The transmission from shaft ‘V’ to
shaft ‘VI’ is through single gear pair, but without change of speed.
 p3 = 1
(vi) Hence, the structural formula for option ‘A’ is,
zA = p1 (x1) p2 (x2) p3 (x3)
or zA = 3 (x1) 2 (x2) 1 (x3)

Now x1 = 1

 x2 = p1 = 3

x3 = 0 (For option A)

 zA = 3 (1) 2 (3) 1 ( ) …(a)

(vii) The number of speed steps for option ‘A’ is,
zA = 3  2  1 = 6
 Option B : Transmission with clutch ‘AA’ disengaged and gear pair
B - B engaged :
(i) The transmission in first two stages (up to shaft III) is same as in option ‘A’.
Hence, p1 = 3

and p2 = 2
(ii) Once the clutch ‘AA’ is disengaged and gear pair B - B is engaged, there is no
transmission from shaft ‘III’ to shaft ‘V’ directly.
 Machine Design - II (GTU) 5-49 Design of Multi-speed Gear Boxes

(iii) The power is transmitted from shaft ‘III’ to shaft ‘V’ through shaft ‘IV’. There is
single speed step between shafts ‘III’ and ‘IV’ and between ‘IV’ and ‘V’.
 p3 = 1

and p4 = 1
(iv) The speed is reduced from shaft ‘III’ to shaft ‘IV’ and from shaft ‘IV’ to shaft
‘V’.
(v) Hence option ‘B’ gives low speed range.
(vi) The fifth stage is between shafts ‘V’ and ‘VI’. The transmission from shaft ‘V’ to
shaft ‘VI’ is through single gear pair but without change of speed.
 p5 = 1
(vii) Hence, the structural formula for option ‘B’ is,
zB = p1 (x1) p2 (x2) p3 (x3) p4 (x4) p5 (x5)

or zB = 3 (1) 2 (3) 1 (x3) 1 (x4) 1 (x5)

But x3 = x4 = x5 = 0

 zB = 3 (1) 2 (3) 1 ( ) 1 ( ) 1 ( ) …(b)

(viii) The number of speed step for option ‘B’ is,
zB = 3  2  1  1  1 = 6
3. Structural formula :
 From Equations (a) and (b) it is seen that, the arrangement is compound type.
 The structural formula for compound speed diagram is given by,
z = zA + zB

= 3 (1) 2 (3) 1 ( ) + 3 (1) 2 (3) 1 ( ) 1 ( ) 1 ( )

or z = 3 (1) 2 (3) [ 1 ( ) + 1 ( ) 1 ( ) 1 ( ) ] …(c)

4. Number of speed steps (z) :
The number of speed steps for gear box is given by,
z = zA + zB = 6 + 6
or z = 12
5. Range ratio (Rn) :
z–1 (12 – 1)
Rn =  = (1.2589) = 12.58
 Machine Design - II (GTU) 5-50 Design of Multi-speed Gear Boxes

6. Minimum spindle speed (nmin) :

nmax
Rn = n
min

1000
12.58 = n
min

 nmin = 79.5

nmin = 79.5 r.p.m.

7. Spindle speeds (nk) :
The spindle speeds are given in Table 5.19.1.
Table 5.19.1 : Spindle Speeds

Speed Spindle Speed, ‘nk’ r.p.m.

Step
Expression Speed
1 n1 = nmin n1 = 79.5

2 n2 = n1  = 80  (1.2589) n2 = 100
2 2
3 n3 = n1  = 80  (1. 2589) n3 = 126
3 3
4 n4 = n1  = 80  (1. 2589) n4 = 159
4 4
5 n5 = n1  = 80  (1. 2589) n5 = 200
5 5
6 n6 = n1  = 80  (1. 2589) n6 = 251.5
6 6
7 n7 = n1  = 80  (1. 2589) n7 = 317
7 7
8 n8 = n1  = 80  (1. 2589) n8 = 398.5
8 8
9 n9 = n1  = 80  (1. 2589) n9 = 501.5
9 9
10 n10 = n1  = 80  (1. 2589) n10 = 631.5
10 10
11 n11 = n1  = 80  (1. 2589) n11 = 795
11 11
12 n12 = n1  = 80  (1. 2589) n12 = 1000

8. Speed diagram :
 The speed diagram in this case is a compound type with option ‘A’ giving six
speeds in high speed range and option ‘B’ giving six speeds in low speed range.
 Machine Design - II (GTU) 5-51 Design of Multi-speed Gear Boxes

 The speed diagram constructed from structural formula,

z = 3 (1) 2 (3) [1 ( ) + 1 ( ) 1 ( ) 1 ( ) ] is shown in Fig. 5.19.2.

Fig. 5.19.2 : Speed Diagram

9. Transmission range :

 From Fig. 5.19.2 it is seen that, the transmission range is maximum in second stage,
third stage and fourth stage.

 The maximum transmission range is,

3 3
(ig)stage =  =  (1.2589) = 2 < 8

 Hence, the maximum transmission range is within the permissible limit.

Example 5.20 :
Draw the suitable speed ray diagram for a 14 speed machine tool gear box having six speeds
for high range operations with ceramic tools. The spindle speed range is between 160 r.p.m.
and 4200 r.p.m. The gear box is driven by 5 kW, 1440 r.p.m. electric motor.
 Machine Design - II (GTU) 5-52 Design of Multi-speed Gear Boxes

Solution :
Given : z = 14 ; zB = 6 ;
nmin = 160 r.p.m. ; nmax = 4200 r.p.m. ;
P = 5 kW ; nem = 1440 r.p.m.
1. Speed range (Rn) :
nmax 4200
Rn = n = 160 = 26.25
min

2. Geometric progression ratio () :

1
(z – 1)
 = Rn
1
(14 – 1)
= (26.25)

or  = 1.2858
3. Spindle speeds (nk) :
The spindle speeds are given in Table 5.20.1.
Table 5.20.1 : Spindle Speeds

Speed Spindle Speed, ‘nk’ r.p.m.

Step
Expression Speed

1 n1 = nmin n1 = 160

2 n2 = n1  = 160  (1.2858) n2 = 206

2 2
3 n3 = n1  = 160  (1. 2858) n3 = 264.5
3 3
4 n4 = n1  = 160  (1. 2858) n4 = 340
4 4
5 n5 = n1  = 160  (1. 2858) n5 = 437.5
5 5
6 n6 = n1  = 160  (1. 2858) n6 = 562
6 6
7 n7 = n1  = 160  (1. 2858) n7 = 723
7 7
8 n8 = n1  = 160  (1. 2858) n8 = 930
8 8
9 n9 = n1  = 160  (1. 2858) n9 = 1195
 Machine Design - II (GTU) 5-53 Design of Multi-speed Gear Boxes

Speed Spindle Speed, ‘nk’ r.p.m.

Step
Expression Speed
9 9
10 n10 = n1  = 160  (1. 2858) n10 = 1537
10 10
11 n11 = n1  = 160  (1. 2858) n11 = 1976
11 11
12 n12 = n1  = 160  (1. 2858) n12 = 2540.5
12 12
13 n13 = n1  = 160  (1. 2858) n13 = 3266.5
13 13
14 n14 = n1  = 160  (1. 2858) n14 = 4200

4. Structural formula :
The gear box is having compound arrangement with six speeds in high speed range and
eight speeds in low speed range.
 z = zA + zB

= 8+6
or z = 222+23 …(a)
 zA = 2  2  2
or zA = 2 (x1) 2 (x2) 2 (x3)
Now, x1 = 1
 x2 = p1 = 2
and x3 = p1  p2 = 2  2 = 4
 zA = 2 (1) 2 (2) 2 (4) …(b)
 zB = 2  3
or zB = 2 (x1) 3 (x2)
Now, x1 = 1

 x2 = p1 = 2

 zB = 2 (1) 3 (2) …(c)

z = zA + zB
= 2 (1) 2 (2) 2 (4) + 2 (1) 3 (2)
or z = 2 (1) [2 (2) 2 (4) + 3 (2) ] …(d)
 Machine Design - II (GTU) 5-54 Design of Multi-speed Gear Boxes

5. Speed diagram :
Speed diagram constructed from structural formula,
z = 2 (1) [ 2 (2) 2 (4) + 3 (2) ] is shown in Fig. 5.20.1.

Fig. 5.20.1