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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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