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Internal Code: MAS3961

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The shaft of a DC motor is connected via a flexible coupling to the input shaft of a helical gearbox. The motor rotates in the clockwise direction as viewed from the + x axis. Bearings A and D are to take up the thrust loads. You are required to work in a team of two to design the gearbox as shown below. Design specification:

• Input power = 5.4 kW
• Input speed = 1,700 rpm
• Output speed = 765 rpm
• KHK stock helical pinion, right hand, transverse module 3 mm, catalogue no. KHG3-18R
• Infinite shaft life
• Bearing requisite life greater than 8,000 hours

Requirements 1. Choose an appropriate KHK stock helical gear to mate with the given pinion. 2. Create a 3D sketch of the input shaft and the pinion, and show all the forces acting on the pinion and bearing reactions at A and B. 3. Calculate the forces acting on the pinion and bearing reactions at A and B. Show steps clearly with appropriate units. 4. Determine the output torque. State any assumption. 5. Select appropriate bearings for bearings A and B from NTN rolling bearing catalogue. Show all relevant calculations and reasoning. Attach the bearing catalogue data with your report. 6. Calculate the bearing life (L 10 ) in hours for bearings A and B.