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Unit 01
design of Machine Tool gearbox
By Dr. SANDIP A. KALE

MECHANICAL ENGINEERING DEPARTMENT TRINITY COLLEGE OF ENGINEERING AND RESEARCH, PUNE

Unit 01 Design of Machine Tool Gearbox
 Introduction to machine tool gearboxes,

 Design and its applications,

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 Basic considerations in design of drives,

 Determination of variable speed range,

 Graphical representation of speed and structure diagram,

 Ray diagram, Selection of optimum ray diagram,

 Deviation diagram
2
 (Full design problem to be restricted up to 2 Stages only)

MECHANICAL ENGINEERING DEPARTMENT TRINITY COLLEGE OF ENGINEERING AND RESEARCH, PUNE

Books for Design of Machine Tool Gearbox
 S.K. Basu and D. K. Pal, Design of Machine Tools, Oxford Pub Co.

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Xerox of III and IV Chapter (Available in Library)

 Machine Tool Design and Numerical Control, N. K. Mehata, McGraw

Hill
Xerox of Second Chapter (Available in Library)

 Design of Machine Elements II, Bhandari V.B., Tata McGraw Hill Pub.
Your personal
3 copy with you

MECHANICAL ENGINEERING DEPARTMENT TRINITY COLLEGE OF ENGINEERING AND RESEARCH, PUNE

 Machine Tool

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 Need of Gearbox

 Machine tools are characterized by their large number of spindle

speeds and feeds to cope with the requirements of machining

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parts of
 Different materials and dimensions
 Using different types of cutting tool materials and
 Geometries
 Operation

 The cutting speed is determined on the bases of,

 The cutting ability of the tool used,
 Surface finish required, and
 Economical considerations 5

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 Need of Gearbox

Tool life more at low machine cost

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T a b c
v st
T = Tool life
C = Cost
v = Cutting speed
s = Feed
t = Depth of cut

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 Need of Gearbox

Cutting Speed

 Dn

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v
1000
v = cutting speed
D = Diameter of work-piece
n = Spindle rpm

Spindle rpm must be set to,

1000 v
n
D
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 Need of Gearbox

 Step-less speed drive

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 Variable Frequency Drive

 Hydraulic

 Stepped drive

 Belt : 2-4 speeds,

Example – Drilling Machine

 Gears : More than 4 speeds

Example – Lathe, Milling Machine, Grinding Machine

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 Gearbox

 A wide variety of gearboxes utilize

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 sliding gears

 friction

 jaw coupling

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 Gearbox

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 Gearbox

 The advantage of a sliding gear transmission

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 Capable of transmitting higher torque and

 Small in radial dimensions.

 Disadvantages

 Changing speeds during running.

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 Gearbox

 The extreme spindle speeds nmax and nmin can be determined by,

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1000 vmax
nmax 
 Dmin

1000 vmin
nmin 
 Dmax

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 Gearbox Speed Steps

4 Speed Gear Box n1, n2, n3, n4

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6 Speed Gear Box n1, n2, n3, n4, n5, n6

9 Speed Gear Box n1, n2, …………., n8, n9

12 Speed Gear Box n1, n2,…………., n11, n12

 How to decide n1, n2,…………., n11, n12 ? 13

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 Laws of Stepped Regulation

 How to decide n1, n2,…………., n11, n12 ?

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1. Arithmetic Progression

2. Geometric Progression

3. Harmonic Progression

4. Logarithmic Progression

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 Laws of Stepped Regulation : Arithmetic Progression

 Difference between adjacent rpm values is constant

n2  n1  n3  n2  Constant  a

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n2  n1  a

n3  n2  a  n1  a  a  n1  2a

nz  n1  ( z  1)a
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 Laws of Stepped Regulation : Arithmetic Progression

 Diameter range speed by speed range can be calculated as below,

1000 v
Upper limit of range Dx 

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 nx
1000 v
Lower limit of range Dx 1 
 nx 1

Diameter range served by this particular rpm

1000 v  1 1 
Dx    
  nx nx 1 
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 Laws of Stepped Regulation : Arithmetic Progression

n nx rpm fx Dx mm DDx mm

n1 30 2.04 212 108.3

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n2 61.4 1.51 103.7 35.1
n3 92.8 1.33 68.6 17.3
n4 124.2 1.25 51.3 10.4
n5 155.6 1.20 40.9 6.9
n6 187 1.17 34.0 4.84
n7 218.4 1.14 29.16 3.66
n8 249.8 1.12 25.5 2.90
n9 281.2 1.11 22.6 2.20
n10 312.6 1.10 20.4 1.9
n11 344 1.09 18.5 1.6
n12 375 16.9 17

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 Laws of Stepped Regulation : Arithmetic Progression

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 For an economical Cutting speed v0, the lowest speed v1 is not
constant; it decreases with increasing diameter.
 Therefore, the arithmetic progression does not permit economical
machining at large diameter range
 The speeds are not evenly distributed and more concentrated and
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closely stepped, in the small diameter range than in the large one.
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 Laws of Stepped Regulation : Geometric Progression

 Ratio of adjacent rpm values is constant

n2 n3
  1

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 nz   z 1
n1 n2
   
n2  n1  n1 

n3  n2  n1 2
For
1 z  12,   1.26
 n3  2
   
 n1 
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 Laws of Stepped Regulation : Geometric Progression

n nx rpm fx Dx mm DDx mm

n1 30 1.26 212 42

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n2 37.5 1.26 170 36
n3 47.5 1.26 134 28
n4 60 1.26 106 21
n5 75 1.26 85 18
n6 95 1.26 67 13
n7 118 1.26 54 11.5
n8 150 1.26 42.5 9
n9 190 1.26 33.5 6.5
n10 235 1.26 27 5.8
n11 300 1.26 21.2 4.2
n12 375 17 20

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 Laws of Stepped Regulation : Geometric Progression

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 The percentage drop from one step to the other is constant, and the absolute
loss of economically expedient cutting speed v is constant all over the whole
diameter range.
 The relative loss of cutting speed vmax/v0 is also constant.
 Geometric progression, therefore, allows machining to take place between
limits v0 and vu independent of the work-piece diameter, where v0 is the
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economical cutting speed and vu is the allowable minimum cutting speed.
c MECHANICAL ENGINEERING DEPARTMENT TRINITY COLLEGE OF ENGINEERING AND RESEARCH, PUNE
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 Laws of Stepped Regulation : Geometric Progression

 Constant loss of economic cutting speed in the whole rpm range.

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 Constant loss of productivity in the whole range of rpm
 Better design features

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 Selection of Range Ratio (Rn)

The following information is essentially required before starting the design of the
gearbox

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1. The highest output rpm (nmax)

2. The lowest output rpm (nmin)

3. The number of speed steps z, into which nmin and nmax can be divided

4. The number of stages u, in which the required number of speed steps

are to be achieved
nmax
Range Ratio Rn 
nmin
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c MECHANICAL ENGINEERING DEPARTMENT TRINITY COLLEGE OF ENGINEERING AND RESEARCH, PUNE

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 Selection of Range Ratio (Rn)

 dn nmax
v Rn 
1000 nmin

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1000v
n vmax
d
d min vmax d max
1000vmax Rn   
nmax  vmin vmin d min
 d min
d max
1000vmin
nmin 
 d max Rn  Rv  RD
Rv = Cutting speed range
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RD = Diameter range
MECHANICAL ENGINEERING DEPARTMENT TRINITY COLLEGE OF ENGINEERING AND RESEARCH, PUNE
 Selection of Cutting speed Range (Rv)

 The fixing of higher speed limit (Vmax) involves productivity loss

in some machining operations in which higher cutting speed is

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permissible

 Very high limit of cutting speed (Vmax) is not practical nor

economical from the machine building point of view.

 Too lower cutting speed reduces tool life and subjected to

productivity loss

 The value of Rv is kept in reasonable limit

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MECHANICAL ENGINEERING DEPARTMENT TRINITY COLLEGE OF ENGINEERING AND RESEARCH, PUNE

 Selection of diameter Range (RD)

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 RD is selected on the basis of statistical study of the working of
similar machine tools

 RD = 4 covers 85 % work pieces

 RD = 6 covers 90 % work pieces

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MECHANICAL ENGINEERING DEPARTMENT TRINITY COLLEGE OF ENGINEERING AND RESEARCH, PUNE

 Selection of Range ratio (Rn)

 The different values for Rn for different machine tools are as

follows

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Machine Tool Rn
Centre lathe, boring machine 40-60
Milling Machine 30-50
Shaping Machine 10
Drilling Machine 15-30
Automatic lathe 8-10
Semi-automatics 16-24
Grinding machines 1-10

 Above values can be increased by 25 % for the future progress

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in machining techniques, cutting tool material and design
MECHANICAL ENGINEERING DEPARTMENT TRINITY COLLEGE OF ENGINEERING AND RESEARCH, PUNE
 No. of Speed steps, Range Ratio and geometric progression

nmax nz
Rn    z 1

nmin n1

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log Rn
z
log 

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MECHANICAL ENGINEERING DEPARTMENT TRINITY COLLEGE OF ENGINEERING AND RESEARCH, PUNE

 Selection of geometric progression ratio

40  40 10  1.06

20  20 10  1.12

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10  10 10  1.26

20 3  20 3 10  1.41

5  5 10  1.58
4  4 10  1.78
10 3 
10 3
10  2.0 29

MECHANICAL ENGINEERING DEPARTMENT TRINITY COLLEGE OF ENGINEERING AND RESEARCH, PUNE

 Selection of geometric progression ratio

f 1.06 1.12 1.26 1.41 1.58 1.78 2.0

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 1
 100
 1 3 5 12 17 22 28 33

(% loss of
economic
cutting )

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MECHANICAL ENGINEERING DEPARTMENT TRINITY COLLEGE OF ENGINEERING AND RESEARCH, PUNE

Standard speed values for different geometric progression ratio

F = 1.12 F = 1.26 F = 1.41 F = 1.58 F = 1.79 F=2

R 20 R 10 R 20/3 R5 R4 R 10/3
10 10 10 10
11.2 11.2
12.5 12.5

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14
16 16 16 16 16
18 18
20 20
22.4 22.4
25 25 25
28
31.5 31.5 31.5 31.5 31.5
35.5
40 40 40
45 45
50 50
56 56
63 63 63 63 63
71
80 80
90 90
100 100 100 100
112
125 125 125 125 31
******
1000 1000 1000 1000 1000 1000
 Recommended values of f in machine tools

Machine Tool Value of f

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Heavy duty machine tool and automats 1.12

Large to medium size GPM and automats 1.26

Medium size GPM 1.41

Medium to small size GPM 1.58

Most commonly used values of f = 1.26, 1.41, 1.58

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 Break of speed steps and the number of transmission stages

log Rn
Number of speed steps are given by z
log 

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The values obtained by equation is rounded to nearest whole number
with a preference given to number which can be break down into
multiples of 2 and 3 as shown in table
Range of z z (Rounded value) Break up

5 to 7 6 23
7 to 8.5 8 2 2  2
8.5 to 10 9 33
10 to 13 12 223
13 to 16 16 2222

Preferred values of z are 2, 4, 6, 8, 9, 12, 16, 18, 24, 27, 32, 36, etc. 33
 Break of speed steps and the number of transmission stages

z = 2u1 X 3u2

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 A multispeed gearbox based on GP is designed in a
number of stages.
 The values
 u1 : number of stages having two speed steps

 u2 : number of stages having three speed steps

 The total number of stages u

u = u1 + u 2
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 Break of speed steps and the number of transmission stages

z 2u1  3u2 u1 u2 u

z = 2u1 X 3u2 2 21  30 1 0 1

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u = u1 + u2 4 22  30 2 0 2
6 21  31 1 1 2
No. of stages for standard
values of f
8 23  30 3 0 3
9z 202u132 3u2 0u 2u 2u
1 2
12
16 22 1
4  30 2
4 01 3 4
2 3
18 21  32 1 2 3
24 23  31 3 1 4
27 20  33 0 3 3
35
32 25 30 5 0 5
36 2 2 2 2 4
 Suppose z number of speed steps are obtained in u number of
transmission stages.
 If p1 is the number of speed steps in first transmission group

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 If p2 is the number of speed steps in Second transmission group

 After second stage we have p1 X p2 speed steps.

 After third stage we have p1 X p2 X p3 speed steps.

 Finally after u stages

Z = p1 X p2 X p3 ……… X p3

For obtaining a particular number of speed steps with minimum

number of gears, it is necessary that

p1 = p2 = p3 ……….. = pu

Z = pu 36

p = z(1/u)
 Break of speed steps and the number of transmission stages

 Suppose a speed on one shaft yields two speed values on the next
shaft. The number of speed steps of a particular transmission group

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p=2
 The transmission ratios that provide the two new speed values must
lie in the following range
1
imax  2 imin 
4
 The maximum reduction of speed is limited to four times to keep the
radial dimensions of the speed box within reasonable limits,
 The maximum increase of speed is restricted to two times due to
limitation of pitch line velocity.
 The transmission range of the group is given by,
imax 37
ig  8
imin
 Break of speed steps and the number of transmission stages

 Suppose there are z speed steps n1, n2,…………. , nz in a particular

transmission group such that,

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n2 n3 n4 nz
  ...... K
n1 n2 n3 nz 1
 Since the speeds on the last shaft of the speed box must constitute
a geometric progression, the following relation must be satisfied,

K X
 Here X is known as characteristic of the transmission group and it
denotes the number of steps of the spindle rpm geometric
progression by which two adjacent rpm values of the particular
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group are separated.
 Break of speed steps and the number of transmission stages

 The transmission group is denoted by p(X)

 p: Number of speed steps in transmission group

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 X : characteristic of the transmission group

3 (1) 2 (4) 39