Abstract
In practice, the cost of a gearbox plays a very important role in the trade. Therefore, reducing the cost of gearboxes is an important task not only when manufacturing the gearboxes but also when designing them. In order to reduce the cost of a gearbox, there are many solutions in which determining the optimal partial gear ratios of a gearbox is an effective measure. This is because it not only the size, the mass but also the cost of a gearbox depends greatly on the partial gear ratios. This work presents a method for calculating the cost function of two-stage helical gearboxes with second-stage double gear-sets based on the mass of the components that construct the gearbox. The cost objective function is minimized to achieve the optimal transmission ratios. Furthermore, screening experiments are carried out with nine important input parameters that have significant effects on the optimum transmission ratio of the second stage. These parameters are the total gearbox ratio, the coefficient of wheel face width of the first stage, coefficient of wheel face width of the second stage, the allowable contact stress of the first stage, the allowable contact stress of the second stage, the output torque, the cost of gearbox housing, the cost of gears, and the shaft cost. The experimental results of were analysed by using the Analysis of Variance (ANOVA) method with the help of Minitab 19 software. The results demonstrate that the effective weight of the input parameters and their interactions on the output response was investigated. Also, a regression model for computing the optimal transmission ratio of the second stage was proposed. This brings significance not only in the design process but also in manufacturing since the gearbox cost can decrease
Highlights
Among many drive systems used in industries such as mechanical drive systems, electric drive systems, pneumatic drives, hydraulic drives, etc., mechanical drive systems are used most widely
From the observation of the slope angles of all straight lines in this figure, the total gearbox ratio ut has the largest influence on the optimum transmission ratio u2
The effect of these parameters on the optimum transmission ratio is much smaller than the influence of the total gearbox ratio
Summary
Among many drive systems used in industries such as mechanical drive systems, electric drive systems, pneumatic drives, hydraulic drives, etc., mechanical drive systems are used most widely This is because it has simple structure, easy design and manufacture, stable working, high reliability and low cost. A mechanical drive system is responsible for reducing the rotational speed and increasing the torque from the motor shaft to the shaft of the working machine It is composed of an electric motor, a gearbox, an external transmission drive (either a V-belt or a chain drive) and a coupling of which the gearbox is the main part. Determining the optimum gear ratios for gearboxs is a topic that attracts the attention of many researchers
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