Design and construction of a parallel axes gear research test rig

In this thesis, a back to back type research test rig is designed and manufactured to study on the transmission error, wear, pitting and oil performance of the gears under controllable conditions. The back to back test rig have test and slave gearboxes connecting with rod and couplings. Static torque is locked into the system via torque clutch mechanism. Power of electric motor only compensates system power losses. Its speed is variable between 0-3000 rpm. Speed of the system can be increased by belt-pulley system. Lubrication of gears and bearings is provided from an oil tank whose capacity is 30 lt/min. On test rig, in addition to these, there are 4 thermocouples, an oil pressure gauge and an oil pump (20 cc). In analytical design of parts, all calculations of test gears, shafts, bearings, torsion rods, couplings and similar are made by using computer programme Ms Excel®. All 3-D and 2-D drawings of test rig components are made by using computer programme Catia® and AutoCAD®. Finite element analysis of some parts are made by using computer programme Msc SimXpert®. All parts of the test rig are manufactured in high precision machines. Key words: Gear test rig design, gear test rig manufacturing, finite element analysis, gearbox design, gearbox manufacturing.