Design a two-stage compound helical gear reducer that has the following design
• Power delivered: 10 kW
• Input speed: 5000 rpm
• Gear ratio: (11 ±1%)
• Input shaft extends 10 cm outside the gearbox casing
• Output shaft extends 15 cm outside the gearbox casing
• All shafts lie in the same plane (Note that it is required that the input and
output shaft are not in line)
• Gear and bearing life should exceed 10,000 hours
• Shafts should have infinite life.
• Low shock levels
1- Define the weakest link that provides the fail-safe feature in your design. This link
should protect the gearbox in case of overloading. This link should fail before any
other part fails in case of overloading.
2- Provide a 3D drawing for the housing. Do not perform any stress analysis for the
housing structure. Show the breather plug, oil drain plug, and the oil level indicator
in your drawing.
3- Create a CAD assembly for the gearbox. Provide an exploded view of the gearbox.
4- Refer to the SKF bearings manual to select the gearbox bearings.
5- Use keys to attach gears to the shaft.
6- Determine the weight and exact dimensions of the gearbox.
8- Create separate tables to summarize:
ü Gear specifications. Do your best to use stock gears (gears that are already
available in the market). Check online catalogues for that.
ü Bearing specifications
ü Key specifications
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