The Design and Analysis of a Single Reduction Gearbox
Given a set of specifications for input speed, gear reduction, safety limits, and power, our team was tasked with designing and analyzing a single stage gearbox using knowledge of machine elements and finite element analysis.
Student were required to research gearbox designs and calculate the dimensions of parts and choose materials based on the design specifications. Shear, strain, and fatigue among others were calculated and used in an Excel document to determine the size of all parts required to complete the project.
The gearbox was then completed in SolidWorks using orings and bushings found commonly off the shelf at suppliers such as McMaster-Carr. A housing was designed around the gear reduction system that would hold the shafts sufficiently, and be liquid tight to allow oil to be used in the system.
Once the design was finished, simulations were run in SolidWorks and compared to the results found both by hand and with Excel to check for accuracy and precision. Life expectancy, vibration analysis and shear stress were calculated in critical parts to ensure product reliability for its lifecycle.
The findings were presented to the class after completion, demonstrating how to properly give a research and development presentation. Facts and finding were presented in a clean and orderly fashion, without delving into the background calculations unnecessarily.
This was a project that not only taught students the principles of engineering design and analysis, but also proper workplace communication and presentation skills.