MCEN3001: Machine Design - Designing a Gearbox - Competitive Design - Engineering Assignment Help

Assignment Task :

An outline of the recommended design process that highlights some of the essential aspects of the gearbox design process is appended below: 

• Prepare an outline design of what you want to achieve and consider all the possible ways it can be done. The simplest solution is usually the best. How will you achieve the required output, and how will you package the gears? What mountings do you require on the gears/bearings and what shaft arrangements? 

• Carefully read the given data, and if required, make the necessary assumptions. Check if you need to comply with any standard values while assuming certain parameters. 

• You must first address the power considerations, as this will help you determine the overall sizing needs for the entire system. Any necessary speed or torque ratio from input to output must be determined before addressing gear sizing. Gears have reasonably high efficiency, and there are negligibly small losses due to factors like friction in the gears and bearings. 

• Select gears of appropriate sizes to achieve the identified ratios. Care should be taken at this point to select the best combination of teeth numbers to minimise the overall package size (i.e. gearbox size). A difference of one tooth on the smallest gear can make a significant impact on size of the overall package. 

• Gather the necessary information, such as gear outside diameters, hub dimensions, face widths, mounting distance, and clearances etc., related to your selected gears. Similar information is also needed for bearings (Note that you will conduct a thorough analysis to select the exact bearings later). You can perform a quick search of on-line gear and bearing catalogues to find the required data – for somewhere to start

• Identify the regions of stress concentration (i.e. stress raisers). Decide the stress concentration factors (Kt values). State criteria for each of the selected values of Kt. 

• Now, identify the critical locations on the counter shaft. The minimum shaft diameter is required to be calculated for all such locations. This must be done by stress analysis at critical locations. You must also include strategies to reduce stress concentrations in the counter-shaft. The proposed strategies must be specific to your shaft – providing a generic discussion will not be accepted. The recommended modifications must be shown implemented in the final design specifications for the countershaft shaft. Do not copy figures/images from the lecture notes. 

• It is the time to determine if there were any anomalies between your assumed values and the final design output. Carry out a point-to-point comparison between the calculated (or assumed) and physical dimensions of the selected components. For example, your calculated shaft diameters may be different to the bore sizes of your chosen gears and bearings. How are you going to overcome such discrepancies? If required, modify your design specifications. 

• Analyse the torque transfer mechanisms, such as keys, splines etc. 

• How do you plan to hold gears and bearings in place? Provide your choice of the available options. For this assignment, strength analysis of such elements/methods is not required. However, complete specifications and their exact locations must be provided. 

ASSUMPTIONS / EXCEPTIONS: 

• While designing the shaft, you may have to consider factors that affect the endurance limit of components. Cyclic/fatigue loading, which is discussed in the Materials unit, deals with these factors. For more information, refer to the recommended textbook. Your best judgment will be acceptable. 

• For this assignment, the mass of the shafts and other components can be ignored. 

• Some of this design does not need detailed calculations, and your own estimates of certain sizes/shapes/configurations will be acceptable. 

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