DESIGN AND ANALYSIS

OF A DOUBLE GEAR
REDUCTION MECHANISM
MCET: 346-001
Mechanical Design III
Samantha Brackett

APRIL 30 TH , 2025
 1

Table of Contents
Introduction ................................................................................................................. 2
Commercial Design Comparison .................................................................................... 2
Design Proposal......................................................................................................... 3
Timeline Comparison .................................................................................................... 4
Appendices ................................................................................................................... 6
Appendix 1 – Gear Kinematics ................................................................................... 6
Appendix 2 – Gear Design .......................................................................................... 7
Appendix 3 – Shaft Design ......................................................................................... 8
Appendix 4 – Bearing Design ..................................................................................... 9
Appendix 5 – Complete Drawing Package ................................................................. 10
 2

Introduction

As a part of the overall course, this project focuses on the design and analysis of a

parallel shaft double reduction spur gear reducer. Building upon the updated Design Proposal,

which identified two commercially available designs for comparison, this report shows a

complete original design created through detailed gear, shaft, and bearing calculations. This

report documents the full design process, compares the final design with the commercially

available designs, and describes areas for improvement.

Commercial Design Comparison

Two commercially available designs were selected for comparison: one from Boston

Gear and another from Regal Rexnord. Both featured double reduction gear reducer boxes

utilizing similar parameters. The design parameters chosen for this project, and later measured,

were found to be both higher and lower than those of the commercial gearboxes (refer to the

Design Proposal below for details). Additionally, the Boston Gear design features a more

ergonomic and streamlined casing compared to the basic box-like casing designed for this

project. Overall, the project’s resulting parameters, as outlined in the Proposal, align logically

with the outcomes observed in the commercial models.

 MD III STUDENT DESIGN PROJECT PROPOSAL
Student's Last Name: Brackett

Desired Input Speed: 1200 rpm

Desired Output Speed: 75 rpm
Input Horsepower Rating: 6 hp
Power Source Category: Uniform (See Table 9-1)
Driven Machine Category: Moderate Shock (See Table 9-1)

Student Proposal and Project Comparison Chart: Timing

Timeline Milestone Due Date Estimate (hours) Actual Time (hours) % Difference
Milestone 1 - Gear kinematics February 7th, 2025 10 0.5 1900%
Milestone 2 - Gear Design February 21th, 2025 10 0.75 1233%
Milestone 3 - Shaft Design March 10th, 2025 15 14.83 1%
Milestone 4 - Bearing Design April 5th, 2025 15 7.99 88%
Milestone 5 - Drawing Package April 26th, 2025 20 24.94 -20%
Written Report May 1st, 2025 20 1.45 1279%
Total Hours 90 50.46

Figure is courtesy of Boston Gear. Other manufactures are available as well.

Student Proposal and Project Comparison Chart: Overall Design Parameters

Commercially Commercially
Design Project Results
Available Design #1 Available Design #2
Name of Manufacturer: Boston Gear Regal Rexnord Brackett Mechanical
Style: DFR
Model Number: 642B-16 MD3 - 01
Size: EL830
Design Parameters
Input speed (rpm) 1160 1750 1200
Output speed (rpm) 72 70 75
Horsepower (hp) 4.51 3 6
Input Shaft Diameter (inches), see dimension X above for 1.125 0.625 0.36
Output Shaft Diameter (inches), see dimension U above for 1.5 1.5 0.9
Overall length (inches), see dimension M above for example 16.59 13.24 19.12

Brackett_MD3_Design_Proposal 1 of 2
 Commercially Available Design #1
Name of Manufacturer: Boston
Gear
Model Number: 642B-16

(Insert figure for Commercially Available Design #1 Here)

Figure from: Source given by Instructor

Commercially Available Design #2

Name of Manufacturer: Regal
Rexnord
Model Number: Style: DFR
Size: EL830

Regal Rexnord (Pg. 178 &

Figure from:
179)

Brackett_MD3_Design_Proposal 2 of 2
 4

Timeline Comparison

As part of this project, each milestone was assigned a timeline, and reasonable time

estimates were provided in the Design Proposal. To maintain accuracy, a timer was used during

the completion of each milestone to record the actual time taken. The percentage differences

between estimated and actual times were also calculated and can be referenced in the Design

Proposal above.

Upon completing all milestones, the largest difference was with Milestone 1 – Gear

Kinematics. The estimated time was 10 hours, while the actual time was only 30 minutes. This

reflected an initial lack of confidence, and an overestimation of the complexity involved. A

similar trend was seen with Milestone 2 – Gear Design, where the estimated time was also 10

hours, but the task was completed in just 45 minutes, proving to be much simpler than

anticipated.

Milestone 3 – Shaft Design was the most accurate, with only a 1% difference between the

estimated and actual time. However, this milestone required two resubmissions and multiple

revisions, as some originally chosen dimensions did not mesh well with the rest of the project.

Milestone 4 – Bearing Design showed an 88% difference but was still closer to the

estimate compared to earlier milestones. This task took less time than expected, mostly because a

3D model had already been created, making it easier to verify the bearings. Some additional

updates to Milestone 3 were necessary as the 3D model was not fully accurate before moving

forward.

Finally, Milestone 5 – Drawing Package took approximately four hours longer than

estimated. Although the drawing package was initially completed in about 20 hours, further
 5

revisions were needed after some instructor feedback, adding roughly four additional hours to the

total time.

Summary

Overall, this project effectively demonstrated the skills and knowledge required to

complete the assignment. Most milestones were achieved faster than anticipated, except for one

that took longer than expected. A key takeaway from this experience was the importance of

maintaining confidence and trusting the abilities developed throughout this and previous courses.

Areas for improvement include ensuring all details are accurate before progressing to the

next phase. At times, the 3D model was not fully updated, specifically regarding the center

distances of bearings and gears, which caused delays in later milestones. Additionally, not all

casing and shaft dimensions were nominal. Some dimensions were at three or four decimal

places, which could lead to increased manufacturing time and cost. Moving forward, it will be

important to manage dimensions more carefully and model with greater logical consistency. This

will help ensure that model views and dimensions remain accurate throughout the design and

drawing phases, ultimately supporting a more efficient and ergonomic final design.
 MD III STUDENT DESIGN PROJECT - MILESTONE 1 SUMMARY
Student's Last Name: Brackett FIGURE 9-11

Data from the Design Proposal

Desired Input Speed: 1200 rpm
Desired Output Speed: 75 rpm
Input Horsepower Rating: 6 hp
Overload Factor, Ko: 1.5 (See Table 9-1)
Design Horsepower, Pdes: 9 hp

Gear Train Kinematics - Determination of Number of Teeth for Each Gear

Number of teeth on N1: 16 Teeth
Number of teeth on N2: 64 Teeth
Number of teeth on N3: 16 Teeth
Number of teeth on N4: 64 Teeth Gear Pair 2 Gear Pair 1

Estimate Diametral Pitch for Each Pair of Gears Using Figure 9-11
Pinion Estimated Diametral
Design
Speed Pitch, Pd, using
Horsepower, Pdes:
(rpm) Chart 9-11
Gear Pair 1 (N1, N2): 1200 9 10

Gear Pair 2 (N3, N4): 300 9 6

Gear Force Calculations Using Estimated Diametral Pitch from Above

Gear pair 1 Tangential force, Wt: 394 Lbf
Gear pair 2 Tangential force, Wt: 945 Lbf
Gear pair 1 Radial force, Wr: 143 Lbf
Gear pair 2 Radial force, Wr: 344 Lbf
Milestone Calculations

(Insert Figure for Milestone Calculations Here)

 MILESTONE 2 - DESIGN OF SPUR GEARS - PAIR 1
Factors in Design Analysis:
LAST NAME: Brackett Alignment Factor, Km=1.0+Cpf+Cma If F<1.0 If F>1.0
Initial Input Data: Pinion Proportion Factor, Cpf = 0.069 0.075 [0.50 < F/DP < 2.00]
Overload Factor: K o = 1.50 Table 9-1 Enter: C pf = 0.075 Figure 9-12
Transmitted Power: P= 6 hp Type of gearing: Open Commer. Precision Ex. Prec.
Design Power P des = 9 hp Mesh Alignment Factor, Cma = 0.272 0.150 0.086 0.053
Diametral Pitch: P d = 10 Fig. 9-11 Enter: C ma = 0.150 Figure 9-13
Input Speed: n P = 1200 rpm Alignment Factor: Km = 1.23 [Computed]
Number of Pinion Teeth: NP = 16 Size Factor: K s = 1.00 Table 9-2: Use 1.00 if P d >= 5
Desired Output Speed: nG = 300 rpm Pinion Rim Thickness Factor: K BP = 1.00 Fig. 9-14: Use 1.00 if solid blank
Computed number of gear teeth: 64.0 Gear Rim Thickness Factor: K BG = 1.00 Fig. 9-14: Use 1.00 if solid blank
Enter: Chosen No. of Gear Teeth: NG = 64 Service Factor: SF = 1.00 Use 1.00 if no unusual conditions
Computed data: Reliability Factor: K R =1.00 Table 9-11 Use 1.00 for R = .99
Actual Output Speed: nG = 300.0 rpm Enter: Design Life: 20000 hours See Table 9-12
Gear Ratio: mG = 4.00 Pinion - Number of load cycles: NP = 1.4E+09 Guidelines: YN, ZN
7 7 7
Pitch Diameter - Pinion: DP = 1.600 in Gear - Number of load cycles: NG = 3.6E+08 10 cycles >10 <10
Pitch Diameter - Gear: DG = 6.400 in Bending Stress Cycle Factor: Y NP = 0.93 1.00 0.93 Fig. 9-21
Center Distance: C= 4.000 in Bending Stress Cycle Factor: Y NG = 0.95 1.00 0.95 Fig. 9-21
Pitch Line Speed: vt = 503 ft/min Contact Stress Cycle Factor: Z NP = 0.89 1.00 0.89 Fig. 9-22
Transmitted Load: Wt = 394 lb Contact Stress Cycle Factor: Z NG = 0.92 1.00 0.92 Fig. 9-22
Secondary Input Data: Stress Analysis: Bending
Min Nom Max Pinion: Required sat = 22,832 psi See Fig. 9-18 or
Face Width Guidelines (in): 0.800 1.200 1.600 Gear: Required sat = 14,669 psi Table 9-9
Enter: Face Width: F = 1.500 in Stress & Hardness Analysis (Through-hardened steel): Contact
Ratio: Face width/pinion diameter: F/DP = 0.94 Pinion: Required sac = 141,010 psi See Fig. 9-19 or
Recommended range of ratio: 0.50 < F/DP < 2.00 Gear: Required sac = 136,585 psi Table 9-9
Enter: Elastic Coefficient: Cp = 2300 Table 9-7 Required hardness of pinion HB = 348 Equations in Fig. 9-19-Grade 1
Enter: Quality Number: A v = 9 Table 9-5 Required hardness of gear HB = 334 Equations in Fig. 9-19-Grade 1
Dynamic Factor: K v = 1.19 Table 9-6 Specify materials, alloy and heat treatment, for most severe requirement.
[Factors for computing K v :] B = 0.630 C= 70.71 One possible material specification:
Reference: N P = 16 N G = 64
Bending Geometry Factor-Pinion: J P = 0.270 Fig. 9-10 SAE 4140 OQT 1000
Bending Geometry Factor-Gear: J G = 0.410 Fig. 9-10 Comments:
Reference: m G = 4.00
Enter: Pitting Geometry Factor: I = 0.120 Fig. 9-17 HB: 341 - Tensile: 168ksi - Yield: 152ksi

Figure 9-10 Shown Below: Figure 9-17 Shown Below:

Jg
I
Jp

OK
 MILESTONE 2 - DESIGN OF SPUR GEARS - PAIR 2
Factors in Design Analysis:
LAST NAME: Brackett Alignment Factor, Km=1.0+Cpf+Cma If F<1.0 If F>1.0
Initial Input Data: Pinion Proportion Factor, Cpf = 0.055 0.069 [0.50 < F/DP < 2.00]
Overload Factor: K o = 1.50 Table 9-1 Enter: C pf = 0.0688 Figure 9-12
Transmitted Power: P= 6 hp Type of gearing: Open Commer. Precision Ex. Prec.
Design Power P des = 9 hp Mesh Alignment Factor, Cma = 0.282 0.160 0.094 0.059
Diametral Pitch: P d = 6 Fig. 9-11 Enter: C ma = 0.160 Figure 9-13
Input Speed: n P = 300 rpm Alignment Factor: Km = 1.23 [Computed]
Number of Pinion Teeth: NP = 16 Size Factor: K s = 1.00 Table 9-2: Use 1.00 if P d >= 5
Desired Output Speed: nG = 75 rpm Pinion Rim Thickness Factor: K BP = 1.00 Fig. 9-14: Use 1.00 if solid blank
Computed number of gear teeth: 64.0 Gear Rim Thickness Factor: K BG = 1.00 Fig. 9-14: Use 1.00 if solid blank
Enter: Chosen No. of Gear Teeth: NG = 64 Service Factor: SF = 1.00 Use 1.00 if no unusual conditions
Computed data: Reliability Factor: K R =1.00 Table 9-11 Use 1.00 for R = .99
Actual Output Speed: nG = 75.0 rpm Enter: Design Life: 20000 hours See Table 9-12
Gear Ratio: mG = 4.00 Pinion - Number of load cycles: NP = 3.6E+08 Guidelines: YN, ZN
7 7 7
Pitch Diameter - Pinion: DP = 2.667 in Gear - Number of load cycles: NG = 9.0E+07 10 cycles >10 <10
Pitch Diameter - Gear: DG = 10.667 in Bending Stress Cycle Factor: Y NP = 0.95 1.00 0.95 Fig. 9-21
Center Distance: C= 6.667 in Bending Stress Cycle Factor: Y NG = 0.98 1.00 0.98 Fig. 9-21
Pitch Line Speed: vt = 209 ft/min Contact Stress Cycle Factor: Z NP = 0.92 1.00 0.92 Fig. 9-22
Transmitted Load: Wt = 945 lb Contact Stress Cycle Factor: Z NG = 0.95 1.00 0.95 Fig. 9-22
Secondary Input Data: Stress Analysis: Bending
Min Nom Max Pinion: Required sat = 21,463 psi See Fig. 9-18 or
Face Width Guidelines (in): 1.333 2.000 2.667 Gear: Required sat = 13,790 psi Table 9-9
Enter: Face Width: F = 2.125 in Stress & Hardness Analysis (Through-hardened steel): Contact
Ratio: Face width/pinion diameter: F/DP = 0.80 Pinion: Required sac = 140,034 psi See Fig. 9-19 or
Recommended range of ratio: 0.50 < F/DP < 2.00 Gear: Required sac = 135,640 psi Table 9-9
Enter: Elastic Coefficient: Cp = 2300 Table 9-7 Required hardness of pinion HB = 345 Equations in Fig. 9-19-Grade 1
Enter: Quality Number: A v = 9 Table 9-5 Required hardness of gear HB = 331 Equations in Fig. 9-19-Grade 1
Dynamic Factor: K v = 1.12 Table 9-6 Specify materials, alloy and heat treatment, for most severe requirement.
[Factors for computing K v :] B = 0.630 C= 70.71 One possible material specification:
Reference: N P = 16 N G = 64
Bending Geometry Factor-Pinion: J P = 0.270 Fig. 9-10 SAE 4140 OQT 1000
Bending Geometry Factor-Gear: J G = 0.410 Fig. 9-10 Comments:
Reference: m G = 4.00
Enter: Pitting Geometry Factor: I = 0.110 Fig. 9-17 HB: 341 - Tensile: 168ksi - Yield: 152ksi

Figure 9-10 Shown Below: Figure 9-17 Shown Below:

Jg I

Jp

OK
 MILESTONE 3 - INPUT SHAFT DESIGN CALCULATIONS FREE BODY DIAGRAMS AND SHEAR-MOMENT DIAGRAMS
STUDENT'S LAST NAME: Brackett Horizontal Vertical
This spreadsheet calculates the minimum shaft diameter using Equation 12-24 for shafts subjected to steady torsion and/or
rotating bending and uses Equation 12-16 when only vertical shear stress is present. Enter forces as positive values when G N1: 394 B #1: 60 B #2: 83
force directions are as shown in the free body diagrams. If the force is opposite from what is shown, enter a negative value.
Shaft Material Data:
Shaft material specification: SAE 1144 Cold Drawn
Tensile strength: s u = 100,000 psi From Appendix 3 or 4
Yield strength: s y = 90,000 psi From Appendix 3 or 4 2.75 2.00 2.75 2.00
Basic endurance strength: s n = 37,500 psi From Figure 5-11
Size factor: Cs = 1 From Table 5-4 B #1: 166 B #2: 228 G N1: 143
Reliability factor: CR = 0.81 From Table 5-3 Note: Force values shown above in red are in opposite direction from what is shown in the FBD diagrams.
Modified endurance strength: Sn' = 30,375 psi Computed
Shaft Length Data:
Center distance between left bearing B1 and gear N1: d1 = 2.750 in Shear Shear
Center distance between gear N1 and right bearing B2: d2 = 2.000 in 250 100
Gear Forces & Moments and Bearing Force (used to create shear-moment diagrams): 200 80
Gear N1 Tangential force, Wt: Fx = 394 lbf
150 60
Gear N1 radial force, Wr: Fy = 143 lbf
Left bearing, B1, radial force: Fx = 166 lbf 100 40
Left bearing, B1, radial force: Fy = 60 lbf 50 20
Right bearing, B2, radial force: Fx = 228 lbf 0 0
Right bearing, B2, radial force: Fy = 83 lbf -50 0 1 2 3 4 5 -20 0 1 2 3 4 5
Torque on shaft: Tz = 315 lbf-in
-100 -40
Moment at Gear N1: Mx = 456 lbf-in
Moment at Gear N1: My = 166 lbf-in -150 -60
Update as needed for each location on shaft: -200 -80
Stress concentration factor: Kt = 2.5
Design factor: N= 1.5
Shaft Loading Data: Bending and Torsion: Moment Moment
Bending moment components: Mx = 0 lb-in 500 0
My = 0 lb-in 0 1 2 3 4 5
Combined bending moment: M= 0 lb-in Computed 400
-50
Torque: Tz = 0 lb-in 300
Minimum shaft diameter: D= 0.00 in Computed from Eq. 12-24
0.00 in If ring groove 200 -100
Shaft Loading Data: Vertical Shearing Force Only:
100
Shearing force components: Vx = 228 lb -150
Vy = 83 lb 0
Combined shearing force: V= 243 lb Computed 0 1 2 3 4 5 -200
Minimum shaft diameter: D = 0.297 in Computed from Eq. 12-16

Summary of the Results of Shaft Diameter Calculations - Design Project - Double Reduction
Torque Bending Moments Shearing Forces Diameter (Minimum) Diameter (Design)
Section Diameter (and related component) T Mx My Vx Vy Kt Feature Preliminary design sizing for Bearing seat diameters denoted by
(lbf-in) (lbf-in) (lbf-in) (lbf) (lbf) shaft. (*) to be specified.
Input shaft end (left) D1 315 0 0 0 0 1.60 Sled Runner Keyseat 0.360 in 0.3600 in
Input shaft end (right) D1 315 0 0 0 0 1.50 Well-Rounded Fillet 0.360 in 0.3600 in
Bearing 1 (left) D2 315 0 0 0 0 in in
Bearing 1 (right) D2 315 0 0 166 60 2.50 Sharp Fillet 0.360 in 0.6693 in
Gear N1 (center) D3 315 456 166 394 143 2.00 Profile Keyseat 0.790 in 0.8750 in
Bearing 2 (left) D4 0 0 0 228 83 2.50 Sharp Fillet 0.297 in 0.6693 in
in in
checked in in
 MILESTONE 3 - INTERMEDIATE SHAFT DESIGN CALCULATIONS FREE BODY DIAGRAMS AND SHEAR-MOMENT DIAGRAMS
STUDENT'S LAST NAME: Brackett Horizontal Vertical
This spreadsheet calculates the minimum shaft diameter using Equation 12-24 for shafts subjected to steady torsion and/or G N3: 944 G N2: 143 G N3: 344
rotating bending and uses Equation 12-16 when only vertical shear stress is present. Enter forces as positive values when force
directions are as shown in the free body diagrams. If the force is opposite from what is shown, enter a negative value.
Shaft Material Data:
Shaft material specification: SAE 1144 Cold Drawn
Tensile strength: s u = 100,000 psi From Appendix 3 or 4 3.00 7.75 2.50 3.00 7.75 2.50
Yield strength: s y = 90,000 psi From Appendix 3 or 4
Basic endurance strength: s n = 37,500 psi From Figure 5-11 B #1: -127 G N2: 394 B #2: 677 B #1: 176 B #2: 312
Size factor: Cs = 1 From Table 5-4
Reliability factor: CR = 0.81 From Table 5-3 Note: Force values shown above in red are in opposite direction from what is shown in the FBD diagrams.
Modified endurance strength: Sn' = 30,375 psi Computed
Shaft Length Data:
Center distance between left bearing B1 and gear N2: d1 = 3.000 in Shear Shear
Center distance between gear N2 and N3: d2 = 7.750 in
400 200
Center distance between gear N3 and right bearing B2: d3 = 2.500 in
Gear Forces & Moments and Bearing Force (used to create shear-moment diagrams):
Gear N2 Tangential force, Wt: Fx = 394 lbf 200 100
Gear N2 radial force, Wr: Fy = 143 lbf
Gear N3 Tangential force, Wt: Fx = 944 lbf 0 0
Gear N3 radial force, Wr: Fy = 344 lbf 0 2 4 6 8 10 12 14 0 2 4 6 8 10 12 14
Left bearing, B1, radial force: Fx = -127 lbf -200 -100
Left bearing, B1, radial force: Fy = 176 lbf
Right bearing, B2, radial force: Fx = 677 lbf
-400 -200
Right bearing, B2, radial force: Fy = 312 lbf
Torque on shaft: Tz = 1260 lbf-in
Moment at Gear N2: Mx = -380 lbf-in -600 -300
Moment at Gear N2: My = 527 lbf-in
Moment at Gear N3: Mx = 1691 lbf-in -800 -400
Moment at Gear N3: My = 778 lbf-in
Update as needed for each location on shaft:
Stress concentration factor: Kt = 2.5 Moment Moment
Design factor: N= 1.5
2000 900
Shaft Loading Data: Bending and Torsion:
800
Bending moment components: Mx = 1691 lb-in
1500 700
My = 778 lb-in
600
Combined bending moment: M= 1861 lb-in Computed
1000 500
Torque: Tz = 1260 lb-in
Minimum shaft diameter: D= 1.33 in Computed from Eq. 12-24 400
1.41 in If ring groove 500 300
Shaft Loading Data: Vertical Shearing Force Only: 200
Shearing force components: Vx = 677 lb 0 100
Vy = 312 lb 0 2 4 6 8 10 12 14 0
Combined shearing force: V= 745 lb Computed -500 0 2 4 6 8 10 12 14
Minimum shaft diameter: D= 0.520 in Computed from Eq. 12-16

Summary of the Results of Shaft Diameter Calculations - Design Project - Double Reduction
Torque Bending Moments Shearing Forces Diameter (Minimum) Diameter (Design)
Section Diameter (and related component) T Mx My Vx Vy Kt Feature Preliminary design sizing for Bearing seat diameters denoted by (*) to be
(lbf-in) (lbf-in) (lbf-in) (lbf) (lbf) shaft. specified.
Bearing 1 (right) D1 0 0 0 -127 176 2.50 Sharp Fillet 0.281 in 0.6693 in
Gear N2 (Center) D2 1260 -380 527 394 143 2.00 Profile Keyseat 0.880 in 1.0000 in
Gear N2 (Right) D2 1260 -380 527 394 143 1.50 Well-Rounded Fillet 0.810 in 1.5000 in
Gear N3 (Center) D3 1260 1691 778 944 344 2.00 Profile Keyseat 1.230 in 1.5000 in
Bearing 2 (left) D4 0 0 0 677 312 2.50 Sharp Fillet 0.520 in 1.1811 in
in in
checked in in
in in
in in
in in
in in
 MILESTONE 3 - OUTPUT SHAFT DESIGN CALCULATIONS FREE BODY DIAGRAMS AND SHEAR-MOMENT DIAGRAMS
STUDENT'S LAST NAME: Brackett Horizontal Vertical
This spreadsheet calculates the minimum shaft diameter using Equation 12-24 for shafts subjected to steady torsion and/or
rotating bending and uses Equation 12-16 when only vertical shear stress is present. Enter forces as positive values when B #1: 354 B #2: 590 B #1: 129 B #2: 215
force directions are as shown in the free body diagrams. If the force is opposite from what is shown, enter a negative value.
Shaft Material Data:
Shaft material specification: SAE 1144 Cold Drawn
Tensile strength: s u = 100,000 psi From Appendix 3 or 4
Yield strength: s y = 90,000 psi From Appendix 3 or 4 3.75 2.25 3.75 2.25
Basic endurance strength: s n = 37,500 psi From Figure 5-11
Size factor: Cs = 1 From Table 5-4 G N4: 944 G N4: 344
Reliability factor: CR = 0.81 From Table 5-3 Note: Force values shown above in red are in opposite direction from what is shown in the FBD diagrams.
Modified endurance strength: Sn' = 30,375 psi Computed
Shaft Length Data:
Center distance between left bearing B1 and gear N4: d1 = 3.750 in Shear Shear
Center distance between gear N4 and right bearing B2: d2 = 2.250 in 800 250
Gear Forces & Moments and Bearing Force (used to create shear-moment diagrams):
600 200
Gear N4 Tangential force, Wt: Fx = 944 lbf
Gear N4 radial force, Wr: Fy = 344 lbf 150
400
Left bearing, B1, radial force: Fx = 354 lbf 100
Left bearing, B1, radial force: Fy = 129 lbf 200
50
Right bearing, B2, radial force: Fx = 590 lbf 0
Right bearing, B2, radial force: Fy = 215 lbf 0
0 1 2 3 4 5 6 7
Torque on shaft: Tz = 5040 lbf-in -200 0 1 2 3 4 5 6 7
-50
Moment at Gear N4: Mx = 1328 lbf-in -400 -100
Moment at Gear N4: My = 484 lbf-in
Update as needed for each location on shaft: -600 -150
Stress concentration factor: Kt = 2.5
Design factor: N= 1.5
Shaft Loading Data: Bending and Torsion: Moment Moment
Bending moment components: Mx = lb-in 0 0
My = lb-in
-200 0 1 2 3 4 5 6 7
-100
0 1 2 3 4 5 6 7
Combined bending moment: M= 0 lb-in Computed
Torque: Tz = 5040 lb-in -400
-200
Minimum shaft diameter: D= 0.90 in Computed from Eq. 12-24 -600
0.96 in If ring groove -300
-800
Shaft Loading Data: Vertical Shearing Force Only: -400
-1000
Shearing force components: Vx = 354 lb
-1200 -500
Vy = 129 lb
Combined shearing force: V= 377 lb Computed -1400 -600
Minimum shaft diameter: D = 0.370 in Computed from Eq. 12-16

Summary of the Results of Shaft Diameter Calculations - Design Project - Double Reduction
Torque Bending Moments Shearing Forces Diameter (Minimum) Diameter (Design)
Section Diameter (and related component) T Mx My Vx Vy Kt Feature Preliminary design sizing for Bearing seat diameters denoted by
(lbf-in) (lbf-in) (lbf-in) (lbf) (lbf) shaft. (*) to be specified.
Bearing 1 (right) D1 0 0 0 354 129 2.50 Sharp Fillet 0.370 in 0.9843 in
Gear N4 (center) D2 5040 1328 484 944 344 2.00 Profile Keyseat 1.170 in 1.2500 in
Bearing 2 (left) D3 5040 0 0 590 215 2.50 Sharp Fillet 0.900 in 0.9843 in
Bearing 2 (right) D3 5040 0 0 0 0 in in
Output shaft end (left) D4 5040 0 0 0 0 1.50 Well-Rounded Fillet 0.900 in 0.9000 in
Output shaft end (right) D4 5040 0 0 0 0 1.60 Sled-Runner Keyseat 0.900 in 0.9000 in
in in
checked in in
 MILESTONE 3 - INPUT SHAFT DESIGN CALCULATIONS

MILESTONE 3 - INTERMEDIATE SHAFT DESIGN CALCULATIONS

MILESTONE 3 - OUTPUT SHAFT DESIGN CALCULATIONS

 Milestone 4 - Bearing Summary Sheet for MD III Project
STUDENT'S LAST NAME: Brackett
Minimum Bearing Bearing Design Checks - All Answers Must be "yes"
Bearing Location Dimensions Based on Shaft Calculations Bearing Data from Table 14-3
Radial Load Average to be an Acceptable Design
Name of Shaft Bearing Location Minimum Bearing Bearing Based on Bearing Bore, d Outside Basic Minimum Diameter Is Bearing Is Bearing Is Bearing Is Bearing
on Shaft Shaft Shoulder Shoulder Bearing Number (inches) dia., D Dynamic Shaft Calculation, Bore Basic Shoulder Shoulder
Diameter, Diameter, Diameter, Calculations, (inches) Load Shoulder (D+d)/2 Diameter, Dynamic Diameter, Diameter,
Dmin at DBS (inches) DBS Cd (lbf) Rating, C Diameter d Load Rating, DBS DBS
Bearing From (inches) (lbf) ,S
Location Milestone 3 Updated (inches)
> C
> <
(inches) based on
Minimum > Minimum (D+d)/2?
Shaft Minimum Shaft
From Bearing
Diameter, Radial Load Shoulder
Milestone 3 Selection
Dmin at Based on Diameter,
Bearing Bearing S?
Location? Calculations?

Bearing #1 0.360 1,993 6303 0.6693 1.8504 3,035 0.866 1.260 Yes Yes Yes Yes
Input 0.790 0.875
Bearing #2 0.297 2,740 6303 0.6693 1.8504 3,035 0.866 1.260 Yes Yes Yes Yes

Bearing #1 0.281 0.880 1.000 1,544 6203 0.6693 1.5748 2,149 0.827 1.122 Yes Yes Yes Yes
Intermediate
Bearing #2 0.520 1.230 1.500 5,303 6306 1.1811 2.8346 6,317 1.457 2.008 Yes Yes Yes Yes

Bearing #1 0.370 1,689 6205 0.9843 2.0472 3,147 1.181 1.516 Yes Yes Yes Yes
Output 1.170 1.250
Bearing #2 0.900 2,814 6205 0.9843 2.0472 3,147 1.181 1.516 Yes Yes Yes Yes
Include calculations (below) for radial load (Pd), bearing life (Ld), and required basic dynamic load (C) for each of the bearings listed in the table above.
 2 1
Notes:
1. See bill of materials on sheet 3
2. All tolerances not specified are +/- 0.05

A A

B B

15.00
15.24
1.55 2.33

18.00
.90
.36

UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Double Reduction
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL

Gear box
MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

A PR-001
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:8 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
See bill of materials on Sheet 3
1

9 2
8
4
B 11
13
B
5 14

3 6
12
7
11
10
10

UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Double Reduction
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL

Gear Box
MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

A PR-001
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:8 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
7 14 13 ITEM NO. PART NUMBER DESCRIPTION QTY.
12
11 2 1 CP-001 Case, Main Body 1
1
2 CP-002 Case, Cover Plate 1
6
8 3 Bearing 6303 Table 14-3 Bearing 2
B 4 Bearing 6203 Table 14-3 Bearing 1
B
3
5 Bearing 6306 Table 14-3 Bearing 1
10
6 Bearing 6205 Table 14-3 Bearing 2
4
5 7 CP-003 Case, Shaft Support 1
Plate
8 SH-001 Shaft Assembly, 1
9 Input
SECTION A-A Shaft Assembly,
9 SH-002 Intermediate 1

10 SH-003 Shaft Assembly, 1

Output
11 HBOLT 0.7500-10x2.75x1.75-N 2
12 HNUT 0.7500-10-D-C 2
13 HBOLT 0.2500-20x0.625x0.625-N 4
14 HNUT 0.2500-20-D-C 4
UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Double Reduction
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL

Gear Box
MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

A PR-001
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:8 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 4 3 2 1
Note: All tolerances not specified are +/- 0.05

18.00 2.60
1.8514
1.8504
15.125

.75

B 1.576
1.575 B
18.00 15.00 .70

DETAIL A
SCALE 1 : 5

4X .20 THRU
1/4-20 UNC THRU
2X R.10 8.25
B

3.00

2X .66 THRU
18.00 17.00 3/4-10 UNC THRU
A

.125 .75

B
14.25 SECTION B-B
A UNLESS OTHERWISE SPECIFIED:
A
NAME DATE

DIMENSIONS ARE IN INCHES DRAWN SB 4/27/25

TOLERANCES:
FRACTIONAL CHECKED TITLE:

Case, Main
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL

Body
MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

CP-001
SAE 1020
B
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:8 WEIGHT: SHEET 1 OF 1

4
SOLIDWORKS Educational Product. For Instructional Use Only. 3 2 1
 2 1
Note: All tolerances not specified are +/- 0.05

15.00
14.25
4X .20 THRU
1/4-20 UNC THRU

B A B
.125

1.1356
2.0484 1.60
2.0472 .5906

1.15
4X R.10
4X R.10
2.50

17.875 17.00
2.8358 .40
2.8346
1.41
.748
1.35

3.25

SECTION A-A
A SCALE 1 : 6
UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Case, Cover
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL

Plate
MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

CP-002
SAE 1020
A
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:12 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
Note: All tolerances not specified are +/- 0.05

B B

.5512 1.8538
1.8532
.6697
.6693

UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Table 14-3
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL

Bearing
MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

ABearing 6303
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:1 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
Note: All tolerances not specified are +/- 0.05

B B
.4724
1.5779
1.5773

.6697
.6693

UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Table 14-3
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL

Bearing
MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

ABearing 6203
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:1 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
Note: All tolerances not specified are +/- 0.05

B B
2.8393
2.8386
.748

1.1816
1.1811

UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Table 14-3
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL

Bearing
MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

ABearing 6306
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:2 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
Note: All tolerances not specified are +/- 0.05

B B

.5906
2.0514
2.0507

.9848
.9843

UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Table 14-3
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL

Bearing
MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

ABearing 6205
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:1 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
Note: All tolerances not specified are +/- 0.05

2.25
.50 1.53

B .60 B
2.25 2X .66 THRU
3/4-10 UNC THRU

8.25
A

2.00 R3.00 SECTION A-A

SCALE 1 : 6

R.05 .5906
2.0484
2.0472 .25

1.13 R.05 1.8514

1.8504
.70
.25
A
.5512
UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Case, Shaft
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL

Support Plate
MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

A CP-003
DRAWING IS THE SOLE PROPERTY OF SAE 1020
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:8 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
All tolerances not specified are +/- ITEM NO. PART NUMBER DESCRIPTION QTY.
0.05 1 SH-001 Shaft, Input 1
2 GK-001 Key Stock 1
3 SSFLATSKT 0.164- 1
32x0.125-HX-C
4 Gear 1 1

B B
1
2 3

A .97
4

A
SECTION A-A

UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Shaft Assembly,
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL

Input
MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

A SH-001
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:2 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
All tolerances not specified are +/- 0.05

B A 2.07 .75 4.20 .75 A

B
1.51

R.07 R.025
2.612 .19

.66905 .66905
.66875 .66875

.8747
.36 .8743
R.03
R.10 .128
.045

SECTION A-A
UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Shaft, Input
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

S-001
SAE 1144 Cold Drawn
A
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:2 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
Note: All tolerances not specified are +/- 0.05

B B

.178 2.60

.216

45° 2X .05

UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Key Stock
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

GK-001
SAE 1020
A
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 2:1 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
Note: All tolerances not specified are +/- 0.05

2.80

B B

R.07 THRU

1.30
.4379
R.4375

UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Gear, Pinion
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

G-001
SAE 4140 OQT 1000
A
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:1 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
All tolerances not specified are +/- ITEM NO. PART NUMBER DESCRIPTION QTY.
0.05 1 SH-002 Shaft, Intermediate 1
2 Gear 3 1
3 Gear 2 1
4 GK-002 Key Stock 1
5 GK-003 Key Stock 1
B 6 SSFLATSKT 0.25- 1
B
20x0.3125-HX-C
7 SSFLATSKT 0.3125- 1
24x0.25-HX-C

6.00 1.08
6
4
2
7
5

UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Shaft Assembly,
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL

Intermediate
MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

A SH-002
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:4 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
All tolerances not specified are +/- 0.05

.75

B A 2.75 3.875 A
B

2X R.13 2X R.1875

3.84 8.88 1.03

.9997
.9993 1.4996
1.4992 1.1807
.66905 1.1803
.66875

R.24 R.03

.13 .193

SECTION A-A
UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Shaft,
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL

Intermediate
MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

S-002
SAE 1144 Cold Drawn
A
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:4 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
Note: All tolerances not specified are +/- 0.05
2.125

R.14 THRU

B B

4.25
.375

.7505
R.7500 .919
2.125

2.125
UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Gear, Pinion
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

G-003
SAE 4140 OQT 1000
A
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:2 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
Note: All tolerances not specified are +/- 0.05

B A B

1.50

3.00 .5004
R.5000

.25

B
R.10 THRU .13

DETAIL B
DETAIL A
SCALE 2 : 5 SCALE 2 : 5

UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Gear
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

G-002
SAE 4140 OQT 1000
A
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:4 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
Note: All tolerances not specified are +/- 0.05

B B

.24 2.75

.234 2X .05
45°

UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Key Stock
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

GK-002
SAE 1020
A
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:1 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
Note: All tolerances not specified are +/- 0.05

B B

.365 3.875

.352 45° 2X .05

UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Key Stock
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

GK-003
SAE 1020
A
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:1 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
All tolerances not specified are +/- ITEM NO. PART NUMBER DESCRIPTION QTY.
0.05 1 SH-003 Shaft, Output 1
2 Gear 4 1
3 GK-004 Key Stock 1
4 SSFLATSKT 0.25- 1
20x0.25-HX-C

B B
3
2
4
2.39

DETAIL B
B
SCALE 1 : 3
1

UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Shaft Assembly,
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL

Output
MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

A SH-003
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:4 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
All tolerances not specified are +/- 0.05

.775 5.41 1.06 3.00

A A
B 2X R.125 2.25 B

.20
4.00

.9840 .8997 .9840 1.2496

.9836 .8993 .9836 1.2492

R.03 R.20
R.03
.117 R.10 .089

SECTION A-A
UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Shaft, Output
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

S-003
SAE 1144 Cold Drawn
A
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:2 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
Note: All tolerances not specified are +/- 0.05

B A B

2.125

4.25 .6254
R.6250
.25
2.00
B .13

R.10 THRU
DETAIL A DETAIL B
SCALE 2 : 5 SCALE 2 : 5

UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Gear
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

G-004
SAE 4140 OQT 1000
A
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:8 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1
 2 1
Note: All tolerances not specified are +/- 0.05

B B

4.00
.24

.237 2X .05 45°

UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
SB 4/25/25
TITLE:
A
Key Stock
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL MFG APPR.

INTERPRET GEOMETRIC Q.A.

PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE DWG. NO. REV

GK-004
SAE 1020
A
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:1 WEIGHT: SHEET 1 OF 1

2
SOLIDWORKS Educational Product. For Instructional Use Only. 1