BOSTON UNIVERSITY

ME 359 Final Project Report

Group #5
Alex Patow, ME 2015
John Griese, ME 2015
Michael Gonzalez, ME 2014
Abby Dutke, ME 2015

12/1/2013

ME359 Final Project Report

Description
The objective of this project is to design a manufacturable prototype gear box. The gear box is
required to have a ratio of 1/240, and a minimum life of 25,000 hours. The input and output shafts are
orthogonal and a maximum of 1.5 inches past the outer surface of the gearbox. The output shaft and its
bearing must support an eccentric load of 50lbf, and have a maximum input shaft rotation speed of
240rpm.
Alex Patow Spec Parts, CAD, CAD Drawings, Presentation and Report
Michael Gonzalez Spec Parts, CAD Drawings, Tolerancing, Presentation and Report
John Griese CAD, CAD Drawings, Tolerancing, Life Analysis, Presentation and Report
Abby Dutke Spec Parts, CAD Drawings, Presentation and Report

Design Review
The final design of the project includes a 10 tooth spur gear, a 100 tooth spur gear, a 1 start
worm, and a 24 tooth worm gear. The input shaft houses the worm, which is paired with the worm gear.
The 10 tooth gear shares the same shaft as the worm gear and is paired with the 100 tooth spur gear.
This gives us a gear ratio of 1/240 and the orientation of the worm and gears makes the input and
output shafts perpendicular. The input and output shafts both protrude 1 inch (nominally) from the
surface of the box. All bearings were specified to support a 50lbf eccentric load with a maximum speed
of 240rpm with a lifetime of 25,000 hours under these most strenuous conditions.

Our gear box housing is made out of 304-Stainless Steel sheet metal which is 0.060 thick. There
are two parts to the housing. One fits into the other and they are connected by self-clinching nuts. The
holes will be drilled into the flat sheet metal pieces, which will then be bent in a set of presses to
achieve the desired shapes.
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ME359 Final Project Report

Ninput = # input teeth

input = input torque

Noutput = # output teeth

output = output torque

input = input rotation speed

output = output rotation speed

GR = gear ratio

Gear Speed Relation

v = velocity at gear tooth contact

R = radius of gear
= rotation speed
DP= diametral pitch

F = force at gear tooth contact

PD = pitch diameters
N= number of teeth

Gear Torque Relation

(

)
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ME359 Final Project Report

( )
( )
( )
(

Gear Trains without Shared Axles

) [(

(
]

Gear Trains with Shared Axles

Tolerance Analyses
We encountered significant problems with SDP-SIs catalog, which led to discrepancies in
tolerancing. When we measured some of the downloaded parts with Smart Dimension in SolidWorks
they were different, about twice as large in certain cases, than the size stated on the website. The most
intensive analysis was for the input shaft because it drives the dimensions in spacing the rest of the
features. For the input shaft (shown below) we performed a detailed circuit analysis. This was not
necessary for the rest of the components for which we did basic tolerance analysis.

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ME359 Final Project Report

Input Shaft
Calculate distance from outer face to 2nd Shaft hole
(J), J = - F.W. - O.S. + W.H + P.D.P
Measurement
Nominal (in) Upper + (in)
Lower - (in)
MAX
MIN
Flange Width (F.W.)
0.045
0.000
0.002
0.025
Outer Shaft (O.S.)
1.000
0.005
0.005
1.005
Worm Hole (W.H.)
1.730
0.005
0.005
1.735
Pitch Diameter Center
(P.D.C.)
0.438
0.000
0.000
0.438
2nd Shaft Hole (J)
1.123
0.010
0.012
1.133
First Groove (G1)
Measurement
Outer Shaft (O.S.)
Bearing Width (B.W.)
First Groove (G1)

O.S + B.W. = G1
Nominal (in) Upper + (in)
Lower - (in)
MAX
1.000
0.005
0.005
1.005
0.188
0
0.005
1.188
0.005
0.01

0.021
0.995
1.725
0.438
1.111

MIN
0.995
0.188
1.193

0.183
1.178

*The greyed cell indicated the critical dimension, i.e. the dimension which, the actual part cannot be
greater or less that without a chance that the part will not fit.
Second Groove (G2)
Measurement
Flange Width (F.W.)
Outer Box Lenth
(O.B.L)
Bearing Width (B.W.)
Second Groove (G2)

- B.L. + F.W. + O.B.L. + F.W. -B.L. = G2

Nominal (in) Upper + (in)
Lower - (in)
MAX
0.045
0.000
0.002
5.811
0.188
5.525

0.005
0
0.005

0.005
0.005
0.019

MIN
0.025

0.021

5.816
0.188
5.530

5.806
0.183
5.506

Bearings (from SDP-SI)

Measurement
Bore Diameter
Outer Diameter
Bearing Width (B.W.)
Flange Width (F.W.)

Nominal (in)
Upper + (in)
0.25
0.5
0.188
0.045

0
0
0
0

Lower - (in)
MAX
0.002
0.003
0.005
0.002

MIN
0.25
0.5
0.188
0.025

0.248
0.497
0.183
0.021

Worm (from SDP-SI)

Measurement
Groove Diameter
Groove Width

Nominal (in)
Upper + (in)
Lower - (in)
MAX (in)
MIN (in)
0.21
0.003
0
0.213
0.21
0.029
0.003
0
0.032
0.029

Retaining Rings (from McMaster-Carr)

Measurement
Bore Diameter
Face Width
Overall Width
Outside Diameter
Hub Diameter
P.D.

Nominal (in) Upper + (in)

Lower - (in)
MAX (in)
MIN (in)
0.25
0.0008
0
0.2508
0.25
0.625
0.875
0.583
0.375
0.5

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ME359 Final Project Report

Second Shaft
Calculate Total Length
Measurement
Bearing Width (B.W.)
Interior Width (I.W.)
Total Length

B.W. + I.W. + B.W.

Nominal (in) Upper + (in)
Lower - (in)
MAX
0.281
0.000
0.005
2.000
0.000
0.010
2.562
0.000
0.020

0.281
2.000
2.562

Nominal (in) Upper + (in)

Lower - (in)
MAX
0.1875
0.0000
0.0020
0.3125
0.0000
0.0030
0.125
0.000
0.005
0.023
0.000
0.002

0.1875
0.3125
0.125
0.023

MIN
0.276
1.990
2.542

Bearings (from SDP-SI)

Measurement
Bore
Outer Diameter
Bearing Width (B.W.)
Flange Width (F.W.)

MIN
0.1855
0.3095
0.120
0.021

Retaining Rings (from McMaster-Carr)

Measurement
Groove Diameter
Groove Width

Nominal (in) Upper + (in)

Lower - (in)
MAX (in)
MIN (in)
0.147
0.002
0.000
0.149
0.147
0.029
0.003
0.000
0.032
0.029

Worm Gear (from SDP-SI)

Measurement
Bore Diameter
Hub Diamter
Hub Projection
Length
P.D.

Nominal (in) Upper + (in)

Lower - (in)
MAX (in)
MIN (in)
0.1869
0.0010
0.0000
0.1879
0.1869
0.625
0.3125
0.5625
1.000

10 Tooth Gear (from SDP-SI)

Measurement
Bore Diameter
P.D.
O.D.

Nominal (in) Upper + (in)

Lower - (in)
MAX (in)
MIN (in)
0.1873
0.0005
0.0000
0.1878
0.1873
0.4167
0.5

Output Shaft
Calculate Total Length
Measurement
Bearing Width (B.W.)
Interior Width (I.W.)
Output Length (O.L.)
Total Length

Nominal (in) Upper + (in)

0.281
0.000
2.000
0.000
1.000
0.005
3.562
0.005

B.W. + I.W. + B.W. + O.L

Lower - (in)
MAX
0.005
0.010
0.005
0.025

MIN
0.281
2.000
1.005
3.567

0.276
1.990
0.995
3.537

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ME359 Final Project Report

Bearings (from SDP-SI)

Measurement
Bore
Outer Diameter
Bearing Width (B.W.)
Flange Width (F.W.)

Nominal (in) Upper + (in)

Lower - (in)
MAX
0.375
0.000
0.002
0.875
0.000
0.003
0.281
0.000
0.005
0.062
0.000
0.002

MIN
0.375
0.875
0.281
0.062

0.373
0.872
0.276
0.060

Retaining Rings (from McMaster-Carr)

Measurement
Groove Diameter
Groove Width

Nominal (in) Upper + (in)

Lower - (in)
MAX (in)
MIN (in)
0.303
0.003
0.000
0.306
0.303
0.039
0.003
0.000
0.042
0.039

100 Tooth Gear (from SDP-SI)

Measurement
Bore Diameter
P.D.
Length

Nominal (in) Upper + (in)

Lower - (in)
MAX (in)
MIN (in)
0.3747
0.0005
0.0000
0.3752
0.3747
4.1667
4.1667
4.1667
0.787
0.787
0.787

Housing
2nd Shaft Hole
Calculate Total Length (parallel to input saft)
Measurement
Nominal (in)
Upper + (in)
Worm Hole (W.H.)
1.730
0.005
Pitch Diameter Center
(P.D.C.)
0.438
0.000
Output Length (O.L.)
1.000
0.005
Total Length
1.168
0.015
Calculate Total Height(perpendicular to input saft)
Measurement
Nominal (in)
Upper + (in)
Input Shaft Hole (I.H.)
1.500
0.005
P.D.(worm)
0.500
0.005
P.D.(10)
0.417
0.001
Total Length
1.958
0.008

B.W. + I.W. + B.W.

Lower - (in)
MAX
0.005

MIN
1.735

1.725

0.000
0.438
0.005
1.005
0.015
1.183
I.H. + (P.D.(worm) + P.D.(10))/2
Lower - (in)
MAX
MIN
0.005
1.505
0.005
0.505
0.001
0.417
0.008
1.966

0.438
0.995
1.153

1.495
0.495
0.416
1.951

Output Shaft Hole

Calculate Total Length (parallel to input saft)
1/2*P.D.(10) + 1/2/*P.D.(100)
Measurement
Nominal (in)
Upper + (in)
Lower - (in)
MAX
MIN
P.D.(10)
0.4167
0.0005
0.0005
0.4172
P.D.(100)
4.1667
0.0005
0.0005
4.1672
Total Length
2.2917
0.0005
0.0005
2.2922

0.4162
4.1662
2.2912

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ME359 Final Project Report

Bearing Fits
Shaft Tolerance
Conditions:
Normal Load
Rotating in Direction of Load
All Shafts are <.71
Tolerance Classification: J5
For All Shafts: Tolerance is +.0002, -.0001
Housing Tolerance:
Conditions:
Outer Ring Stationary
Housing Not Split Axially
Tolerance Classification: H6
For All Shafts: Tolerance is +0, -.0005

Component Life Analyses

Requirements

50lbf over hung load at output shaft

Output shaft is 1.5 max
Max speed of 240 rpm
Life of 25,000 hours

Assumptions

Assume no axial load, all load radially

Wear on the gears should be negligible compared to wear on the bearings
Weight of the shaft and shaft components is negligible compared to the 50lbf eccentric load

Force Analysis
Where:
P = dynamic load;

x = .6 (from tables);

Fr = 50lbf

Lifetime Analysis
( )
Where:
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ME359 Final Project Report

m=3 (ball bearings);

P=dynamic load;

C=dynamic load rating;

L10=life in millions of hours

Input shaft:

)
)

All Gears with 0.375 Bore

All bearings are rated for well over 50lbf static load and also well over the 30lbf dynamic load,
including a 1.5x safety factor. Even adding that 50lbf load, the static load rating (273lbf) exceeds
the minimum requirements for both the input and output shafts.
We specified our bearings to the input rotational velocity. Any section between input and
output will be rotating slower than the input velocity.

Work Estimate and Actual

Preliminary Work Estimate:
Part/Assy Description
Sprocket
Shaft
Body
Assembly
Arm 1
Arm 2
Arm Assembly 1
Arm Assembly 2

Responsible Engineer
Alex Patow
Mike Gonzalez
John Griese
Abby Dutke
Alex Patow
Mike Gonzalez
John Griese
Abby Dutke

Model Time
Completion Estimate
[min]
45
45
30
60
30
30
45
45

Drawing Time
Completion Estimate
[min]
30
30
30
30
30
30
30
30

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ME359 Final Project Report

Actual Work Estimate

Part/Assy Description
Spec/Find PartsWorm & Worm Gear
Spur Gears
Bearings
Retaining Rings
Self-Clinching Nuts
CADBox
Input Shaft
Output Shaft
Assembly
Modify Downloaded CAD Models
CAD DrawingsWorm
Worm Gear
10 Tooth Spur Gear
100 Tooth Spur Gear
Box Pt 1
Box Pt 2
Input Shaft
Output Shaft
Assembly
WrittenTolerancing
Life Analysis
Project Report
Project Presentation

Responsible Engineer
\\\\\\\\\\\\\\\\\\\\\\\
Alex & Mike
Alex & Mike
Alex & Abby
Alex & Abby
Alex
\\\\\\\\\\\\\\\\\\\\\\\
Alex
Alex & John
Alex & John
Alex
Alex
\\\\\\\\\\\\\\\\\\\\\\\
Alex & Abby
Alex & Abby
Alex
Alex
Mike
Mike
Alex & John
Alex & John
Alex
\\\\\\\\\\\\\\\\\\\\\\\
John & Mike
John & Abby
Abby & Mike & John &
Alex
Abby & Mike & John &
Alex

Completion Time
Estimate
[min]
\\\\\\\\\\\\\\\\\\\\\\\
60
60
20
15
5
\\\\\\\\\\\\\\\\\\\\\\\
60
45
45
60
45
\\\\\\\\\\\\\\\\\\\\\\\
30
30
20
20
30
30
40
40
45
\\\\\\\\\\\\\\\\\\\\\\\
480
150
300
210

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ME359 Final Project Report

Bill of materials
ITEM NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

PART
NUMBER
102
101
103
104
602
603
601
201
202
203
301
302
704
703
502
501
503
702
701

DESCRIPTION

VENDOR

24 TOOTH WORM
1 FLUTE START
10 TOOTH SPUR
100 TOOTH SPUR
SECOND SHAFT
OUTPUT SHAFT
INPUT SHAFT
INPUT SHAFT
SECOND SHAFT
OUTPUT SHAFT
BOX PT. 1
BOX PT. 2
PEM NUT
6-32 MACHINE
SIDE-MOUNT
SIDE-MOUNT
SIDE-MOUNT
SHAFT PIN
KEY

SDP-SI P/N: A 1B 6-N24024

SDP-SI P/N: A 1C55-N24
SDP-SI P/N: S1084Z-024A010
SDP-SI P/N: S1VS24-100F1524
SDP-SI P/N: A 7Y55-FS3118G
SDP-SI P/N: A 7Y55-FS8737G
SDP-SI P/N: A 7Y55-FS5025G
MCMASTER-CARR P/N: 8984K823
MCMASTER-CARR P/N: 8984K823
MCMASTER-CARR P/N: 8984K823
MCMASTER-CARR P/N: 8983K62
MCMASTER-CARR P/N: 8983K62
PEM P/N: S-632-0 ZI--N
MCMASTER-CARR P/N: 91735A142
MCMASTER-CARR P/N: 97431A280
MCMASTER-CARR P/N:97431A300
MCMASTER-CARR P/N:97431A320
MCMASTER-CARR P/N: 92373A106
MCMASTER-CARR P/N: 98535A130

MANUFACTURING
PROCESSES
DRILL

MILLING

TURNING/DRILL
TURNING/MILLING
TURNING/MILLING
SHEET METAL
SHEET METAL

MILLING

QTY.
1
1
1
1
2
2
2
1
1
1
1
1
8
8
2
2
2
2
1

Drawings
(Attached)

Page 10 of 10