Overall

Design a single-reduction gearbox for a Mini Baja buggy

Goal of this Code

Create a package of code capable of designing a shaft based on a set of given requirements.

Design Requirements for Assignment

Gear Analysis

• Input power of 9.5 HP
• Input speed of 3000 rpm
• Output speed of 400 $\pm$ 1% rpm
• Helical gears with helix angle $\psi = 30\degree$ and a normal pressure angle $\phi_n = 20\degree$
• Pinion and gear to operate for 1000 hours at 90% reliability
• Commercial enclosed unit
• Uncrowned teeth
• Not adjusted at assembly or lapped
• Use $K_s = 1$ and $C_f = 1$
• Light shock load from engine and moderate shock load from wheels
• Safety factors against bending and wear are to be $S_F = S_H = 1.2$

Shaft Analysis

• Design for infinite life
• Material is AISI 1010 CD with $S_{ut} = 53$ ksi and $S_y = 44$ ksi