The document discusses a project to study the methodology and analysis of a gearbox. It provides information on the internal and external guides for the project, submitted by 4 students. It then discusses the company profile of Chetna Pumps, which manufactures bearing, gearboxes and other equipment. The abstract indicates the project will study how gearbox performance is affected by various parameters like geometry, material, lubricant and operating conditions. It will focus on lubricant selection and how heat generation can decrease lubricant properties and affect gearbox performance. The document outlines the methodology to be used, including gearbox maintenance processes, lubrication and vibration analysis, defect analysis, literature review and objectives to determine power losses of different industrial gear oils.

1. ““To Study Methodology and Analysis of Gearbox”To Study Methodology and Analysis of Gearbox”
Internal Guide by:-
Mr. Vishal Naik
External Guide by:-
Mr. Jitendrakumar Prajapati
(9824432906)
Submitted By:-
1. ARVIND RAJPUT(110480119018)
2.MILAN PATEL(110480119033)
3.AKASH PATEL(110480119013)
4.DHARMESH
DHANDHUKIYA(110480119073)

2. Company Profile
 CHETNA PUMPS, formerly known as CHETNA PUMPS
PVT. LTD.(CPPL) started manufacturing operations since
(1989) located in odhav GIDC, Ahmedabad ,Gujarat ,India.
 The company is focused in economic of material handling
equipment mainly bearing, gearbox, pump lubricant, Oil and
water lubricant, conveyor , feeder etc.
 In addition company also manufacturing turbine pumps and
manufacturing of oil and water lubricant .
 Equipment manufacturing by company conforms to validate
engineering and IS standards, national and global.

3. Abstract
On the bases of literature review it can be seen that gear box performance depends on
many parameters like gear teeth geometry, gear material, lubricant of gear, loading and
working condition.
Among of the above parameters the gear teeth geometry, material and lubricant oil
are very important factor for incense and decrease the performance of gear system.
 The gear oil selection processer is very difficult task in industrial application for
incense performance of gear system. In lubricant oil the lubricant viscosity is most
important factor for selection of gear oil in different industrial application.
 During working condition the heat is generated, when the two teethes are meshes
together. Because of the heat generation inside the gear box, the viscosity of the oil is
decrease and that is ultimately changed in oil properties. This change in gear oil
property will decrease gear tooth hardness, oil level and speed of gear and increase
vibration, noise, wear and power losses.
The power loss is due to interaction between the lubricant and the rotating/moving
elements. These losses are the sum of squeezing, churning and windage power losses.

4. Gearbox Maintenance
 To make sure equipment keep running optimally, gearbox
maintenance is necessary so equipment will be looked after
with regular checkups and preventive maintenance performed.
 On maintenance programme include:-
1. Vibration measurements
2. Visual and videoscopic inspection
3. Oil analysis
4. Non-destructive research
5. Wear protection through laser clading

5. Lubrication and vibration analysis:-
 Beside gearbox repair, equally important is
discovering the root cause of the gearbox failure in
order to avoid unplanned machine down time in the
future. To pinpoint equipment failure we perform
oil analysis, vibration measurement through visual
inspection, for instance examination of abrasive
wear performs and gear tooth pitting.

6. Root cause failure analysis:-
 To determine failure root
cause we both oil
analysis and vibration
analysis combined with
visual inspections. These
diagnostic techniques
are usually requried to
moniter the condition of
plant machinery and to
control the cause of
machine failure.

7. Gearbox analysis - Oil
analysis :-
 In many cases , gear problem
result from contaminated or
insufficient oil. Oil filter
contamination could cause gear
tooth damage, sometimes
insufficient lubrication causes
metal to metal contact with
abrasive wear as a result.
 Oil analysis provides important
information on wear modes and
possible gearbox lubrication
problems. On the other hand,
visual inspections of wear
patterns and gear tooth pitting
can reveal lubrication problems
e.g oil leakage, improper

8. Vibration analysis:-
 Vibration analysis is an
effective technique for
monitering the condition of
gears and determines the
root cause of machine
failure. We are able to
carry out on-site vibration
measurements detecting
various sorts of gearbox
problem:-
 Gear damage
 Alignment Error
 Imbalance
 Looseness
 Bearing defect

9. Defects in Gear and Gearbox:-
Failure
Mechanisms
Reason fordamage Name of the
process
Result
Mechanical
damage
Permanent
indentation creating
gear meshing
Brinelling Indentation
Crack damage Manufacturing
defector stress due
to overload
Crack Loss of
dimensioning
Wear damage Gradual
deterioration
Scuffing
-

10. Insufficient lubrication
and contamination
Friction - Accelerate scuffing
Incorrect design Poor choice of
bearing type or
sizefor required
operation
Low load carrying
capacity or low speed
rating
Thermal instability Large temperature
difference builds up
It causes the bearings
to lose internal
clearance and
become pre-loaded
which results in
increase in heat
generation.
Misalignment Manufacturing or
setting up errors,
elastic deflection of
component under
load , thermal
expansion
Leads to premature
pitting, cage wear
and finally failure.
Defects in Gear and Gearbox:-

11. Literature Review

12. SR NO TITLE INVENTORS
1 Assessing the energy efficiency of gear
oils via the FZG test machine
D.J. Hargreaves
Anton Planitz
Conclusion:-
On the basis of paper results, it was found that the power required running
the best and worst performing oils varied by 14.6%. This represents a
significant reduction in energy requirements and also the potential to
minimize the running costs of industrial machinery. The oils of superior
performance were generally seen to run at lower temperatures. They were
also noted to be of higher cost.

13. SR NO TITLE INVENTORS
2 Influence of tooth profile and oil formulation
on gear power loss
Luis Magalhaes,
RamiroMartins,
CristianoLocateli,
JorgeSeabra
Conclusion:-
On the basis of the paper results, the discussions and conclusions that when gears
311 were replaced by gears 611 the stabilization temperatures decreased. When
lubricated with gear oils M1, P1 and E2, respectively indicating a significant
reduction of the gear friction torque loss. The experimental results also showed that
oils P1 and E2 generated lower stabilization temperatures than the mineral oil M1.
This indicates, they generated lower torque loss and consequently promote a lower
friction coefficient between gear teeth than the mineral oil.

14. SR NO TITLE INVENTORS
3
Tribological properties of an environmentally
adopted universal tractor transmission oil
(UTTO) based on vegetable oil
Boris krzan ,
joze vizintin
Conclusion:-
On the basis of the paper results conclude that Ester based oils show lower friction
coefficient than higher additivated mineral based oils but promote higher wear. Gear
protection properties of the vegetable based oils are better or equivalent than of the mineral
based universal tractor transmission oil. FZG pitting resistance investigations show
significantly better results for the ester based oils, especially for the high oleic sunflower oil
formulation. Laboratory hydraulic system test results show that the high oleic sunflower oil
formulation could match mineral based universal tractor transmission oil for applications
where operating temperatures are reasonable (70 °c in steady state). Investigations in a spur
gear test rig show better thermal oxidative stability for mineral universal tractor transmission
oil compared to the high oleic sunflower universal tractor transmission oil formulation at
constant operating test oil temperature of 80 °c.

15. SR NO TITLE INVENTORS
4
Power losses at low speed in a gearbox
lubricated with wind turbine gear oils with
special focus on churning losses
Pedro M.T. Marques,
Carlos M.C.G. Fernandes,
Ramiro C. Martins,
Jorge H.O. Seabra
Conclusion:-
In this study, gear oils were tested for power loss behavior in a two stage
multiplying gearbox, on a back-to-back test rig with recalculating power. The tests
were performed at low input speeds and high input torques. The polyalkylene
glycol oil showed the lowest operating temperatures. poly-α-olefin and mineral +
40% of PAMA performed identically while the Mineral displayed the highest
operating temperatures.

16. SR NO TITLE INVENTORS
5
The tribological performance of DLC-coated
gears lubricated with biodegradable oil in
various pinion/gear material combinations
M. Kalin,
J. Vizintin
Conclusion:-
On the basis of the work results, concluded that Experimental conditions and by using high quality
biodegradable oil, the contacts of W-DLC/WDLC- coated gears could importantly reduce the oil
temperature and provide satisfactory wear resistance up to A contact pressure of about 1.4 GPa.
Despite the reduced temperature and friction even at higher loads (1.4–1.8 GPa, i.e., FZG stage 10–
12), these conditions cannot be recommended for self-mated coated gears because it will result in high
wear of the coating and lead to premature wear-through of the coating. All the material combinations
that consist of one or two steel gears result in higher oil temperatures than the WDLC/ W-DLC-coated
gears over the whole range of loads and did not vary significantly for the various combinations.

17. SR NO TITLE INVENTORS
6 Hydraulic losses of a gearbox: CFD analysis and
experiments
CarloGorla, FrancoConcl,
Karsten Stahl, Bernd-Robert
Hohn, Klaus Michaelis,
Hansjorg Schultheib, Johann-
Paul Stemplinger
Conclusion:-
The results of the experiments confirm that the CFD represent valid method to predict
power losses. The error in the predictions for the analyzed cases is always lower than 8 %
in particular the tip diameter has been changed from 96.5 to 102.5 mm while the tooth
width has been changed from 20 to 40 mm.

18. SR NO TITLE INVENTORS
7 Influence factors on gearbox power loss Bernd-Robert Hohn, Klaus
Michaelis and Michael
Hinterstoiber
Conclusion:-
No load losses can be reduced, especially at low temperatures and Part load conditions when using low
viscosity oils with a high viscosity index. This in turn influences the cooling properties in the gear and
bearing meshes. Bearing systems can be optimized when using more efficient systems than cross
loading arrangements with high preload. Low loss gears can contribute substantially to load dependent
power loss reduction in the gear mesh. Besides operating conditions no load gear losses mainly depend
on immersion depth in sump lubricated gearboxes as well as on lubricant viscosity. And also
conclusions that, in some applications only the simple change to a highly efficient lubricant can save
some 20% power loss.

19. SR NO TITLE INVENTORS
8
An experimental investigation of the
influence of the lubricant viscosity and
additives on gear wear
Timothy L, Krantz,
Ahmet Kahraman
Conclusion:-
The results indicate that the wear rates are strongly related to the viscosity of the
lubricant. Lubricants with larger viscosity result in larger lambda ratios and lower
wear rates.

20. SR NO TITLE INVENTORS
9
Prediction of overall efficiency in multistage
gear trains
James Kuria, John Kihiu
Conclusion:-
On the basis of the paper results finally conclude that overall efficiency of a gear
system is the first step in improving the efficiency of the system. One way to
conduct efficiency improvements is to carry out analysis on the effect of gear
design parameters, lubricant properties and housing arrangement on the efficiency
of the gear system.

21. SR NO TITLE INVENTORS
10
Investigations on the power losses and
thermal effects in gear transmissions
G Koffel, F Ville, C
Changenet, P Velex
Conclusion:-
From this experiment and work it is confirmed that tooth friction appears as the main
source of dissipation in low–medium-speed gear transmission. To accurately evaluate
these power losses, it is necessary to develop a thermo mechanical model that includes a
precise description of the tooth contact frictional properties. The lubricant temperatures
at the tooth contacts should also be precisely determined since it controls part of the
dissipation process. Two specific models have been presented and combined, which rely
on the formula for tooth friction and on a thermal network for local temperature
calculations. The theoretical results compare well with the measurements obtained from
an industrial test rig and stress the fact that thermo-mechanical couplings cannot be
ignored in power loss simulations.

22. ProblemStatement
From the literature survey it is seen that the power losses calculation is important for
increase the gear performance.
The power losses in gear system are depends on types of gear oil and operating
condition of gear system.
There are number of gear oils are available in the market. But the selection of the
gear oil is very difficult task for industries to increase the performance with economy.
 So my problem statement is “To find out the power losses for different gear oils on
operating condition and alternative of it.”

23. Objective of Work
From problem statement the objective of work is to find out power losses by
using industrial gear oils and alternative oil.
For this following steps are needed to be perform:-
1.Modelling of Gearbox
2.CFD analysis of gear oil in Anysis

24. Impact Statement
Improved availability and reliability of primary process
Alignment error can be avoided
Fewer unplanned maintance
Better risk and safety management
Reduction of repair cost

25. Questions

26. THANK YOU