Two-stage-gearbox-desing

Fig. 1. Exploded view of gearbox components

This team-based project focused on the design, analysis, and validation of a two-stage spur gearbox intended to transmit 14 hp at 1500 rpm to a final output speed in the 66–77 rpm range. The gearbox employed two identical reduction stages, requiring coordination of gear geometry, shaft design, and structural integrity to meet performance and reliability requirements.

Fig. 2. Animated exploded view of gearbox components.

The overall objective was to produce a mechanically sound gearbox capable of handling the specified power and speed reduction while remaining manufacturable and scalable for prototyping. This involved calculating stress for different components of the gearbox as well as accounting for an infinite life endurance limit and a 2.5 safety factor.

Fig. 3. Results of bending stress script for all gears (MATLAB).

Fig. 4. snapshot of SIMULINK gearbox model

Most of my contributions related to calculating stresses at the gear teeth and 3D modeling the gearbox. I created a MATLAB script in order to iterate calculations quickly. This allowed our team to verify the suitability of different materials as well as define the face width for the gears. Additionally I created a SIMULINK model which imported variables from the stress simulation. Using these tools our team was able to verify that the calculated numbers were on the required range.

Fig. 5. FEA report snapshots of most stressed sections.

Part of this project required us to verify our calculations using finite element analysis. This involved researching appropriate ways to apply loads and constraints to our model. I found this youtube channel, which provided a lecture on how to accomplish this. Using the FEA report our team was able to verify that the most stressed sections agreed with the calculated values on the matlab scripts.

For more information and files about this project, please visit the repository.