Design and Optimization of a Two-Stage Gearbox Using GearTrax
01 Jan 2021-pp 445-477
TL;DR: In this article, the design and optimization of a two-stage reduction gearbox for BAJA All-Terrain Vehicle (ATV) transmission system is discussed. And the required reduction ratio of the gearbox is calculated based on the CVT's high and low-end ratios and different road resistances.
Abstract: The ATV transmission system comprises a CVT gearbox along with the axles and hubs which in turn drives the vehicle. The gearbox coupled with CVT provides optimal torque and power at all times. This paper focuses on the design and optimization of a two-stage reduction gearbox for BAJA All-Terrain Vehicle. Based on the CVT’s high- and low-end ratios and different road resistances, the required reduction ratio of the gearbox is calculated. Also, the gradeability factor and maximum acceleration required were the factors taken into account for determining the reduction ratio. Standard AGMA procedures were utilized to scrutinize the design of gears and shafts by using force equations.
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TL;DR: In this paper , a single stage reduction gearbox was designed and optimized using Fusion 360. The velocity ratio for the gearbox is set as 4.5 Nm, which is the minimum required torque and traction to drive the wheels.
1 citations
30 Aug 2022
TL;DR: In this paper , the authors discussed the materials suitable for the manufacturing of gearbox casing using 3D printing technology and compared the different materials based on maximum deformation, maximum stress, and vibrations frequencies with the conventional used material.
Abstract: This paper discusses the materials suitable for the manufacturing of gearbox casing using 3D printing technology. Based on the research of different materials that can be used for 3D printing manufacturing, materials based on strength and availability for manufacturing were considered. Using Ansys 2020 static structural analysis, stress analysis, vibrational, and harmonic analysis were performed. Based on the results, comparison of the different materials based on maximum deformation, maximum stress, and vibrations frequencies with the conventionally used material. The basic aim of this research was to reduce the weight of the existing gearbox casing and find a suitable material that is lightweight as well as suitable for mass production for casing using 3D printing.
TL;DR: In this paper , an efficient composite spur-worm gear system was designed for thermal hot-press applications by implementing analytical calculations with comparing different simulation studies to determine the overall strength and safety of the gears.
30 Aug 2022
TL;DR: In this article , a 3-stage gearbox is designed for mining conveyer belt with the objective of reducing the power consumption of the belt by reducing the gear ratio and the total deformation.
Abstract: AbstractReduction Gearbox are widely used in many industrial applications like Conveyer belts in underground mines, Extruders, Cranes, Crushing Machine, etc. which require high power to function. This paper focuses on designing an optimized 3-stage gearbox. 3-Stage gearbox is chosen as it can work under high gear ratio very efficiently and effectively for speed reduction. The motive to develop a new gearbox is to improve in terms of safety, durability, and efficiency. Helical gears are chosen for gearbox design as they are extensively used in industrial operations for power transmission under heavy loads with smoother and noiseless operation. In this paper the gearbox is designed, considering the requirements of a mining conveyer belt. The gearbox is modeled using Solidworks and then analyzed based on finite element analysis method using Ansys workbench. FEA analysis is conducted to measure and analyze the safety factor, shear stress and total deformation. Finally, the optimal design of gearbox is achieved to meet functional as well as reliability requirements in the field.KeywordsIndustrial gearbox3-stage gearboxHelical gearGear analysis
References
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TL;DR: The gear design that considers the contact stress in a pair of mating gears is more severe than that of the AGMA standard.
90 citations
TL;DR: In this article, the authors investigated the role of surface finish and surface finish on gear wear and found that the wear on the gear flanks depended on the lubricant film thickness and it was higher for the milled gears.
Abstract: One of the main gear damage mechanisms is the formation of pitting and spalling on the tooth flank. Several factors have significant influence on the damage formation, such as: contact stress level; tooth profile type; relative contact speed; surface finish and lubrication conditions. This work comprehends the global observation of all such parameters and was carried out to explain the phenomena related to this wear mechanism. The wear test equipment uses the power recirculation principle and is commonly known as FZG test rig. The gears were made from AISI 8620 steel and had two types of surface finishing (by shaving or by milling). The wear experiments were performed with two torque stages: 135 N.m (running-in) and 302 N.m (steady-state), and two test temperatures: 60oC (running-in) and 90oC (steady-state). The wear level was determined by using image analysis. In order to calculate the specific film thickness and friction coefficient, the roughness of tooth flank was measured at each test stop. After the experiments were completed, it was possible to confirm that, for both manufacturing processes, the boundary lubrication regime was adopted at the tooth flank and the specific film thickness presents a different behavior when compared to addendum, pitch diameter and deddendum regions. The wear on the gear flanks depended on the lubricant film thickness and it was higher for the milled gears.
31 citations
10 Jul 2017
11 citations
TL;DR: In this study, a comprehensive investigation was conducted into the solution of the spur gear design problem in metaheuristic optimization methods, and it was shown that the new methods demonstrated significantly improved performance in solving the Gear design problem compared to existing methods.
Abstract: The design of gears with a minimum weight is an optimization problem that has been widely discussed in the literature. Various recent metaheuristic optimization methods, along with the conventional...
9 citations