Design and Performance Analysis of Gearbox for Industrial Application.

Abstract

This thesis explores the design and performance analysis of industrial gearboxes, emphasizing the critical stresses that affect their operational efficiency and durability—namely, contact stress and bending stress. Industrial gearboxes play a pivotal role in transmitting mechanical power in various heavy-duty applications, making their reliability a key factor in maintaining optimal system performance. The primary objective of this study is to investigate the impact of gear design parameters on the performance and longevity of gearboxes under high load conditions. The research employs theoretical calculations and finite element analysis (FEA) to model and analyze the gear contact stress and bending stress in spur gears, helical gears, and bevel gears commonly used in industrial settings. For contact stress, the analysis utilizes AGMA theory to calculate the stress distribution between gear teeth in meshing, identifying areas susceptible to surface fatigue and pitting. In parallel, the bending stress is analyzed using the AGMA equation, highlighting regions at the gear tooth root that are prone to fatigue failure. Both analyses are validated through simulation and real-world case studies to ensure accuracy. The findings from this research provide a comprehensive understanding of how design factors such as gear geometry, material selection, surface treatments, and lubrication influence the stress distribution and overall performance of industrial gearboxes. Additionally, this thesis proposes optimized design strategies to enhance the durability of gearboxes by minimizing stress concentrations, thereby reducing the risk of gear failure and extending operational life. Ultimately, the study aims to contribute valuable insights into gearbox design optimization for the chemical, manufacturing, and energy industries, where reliable and efficient power transmission is essential.