It is required to design a single stage spur / helical gear reducer

It is required to design a single stage Spur / helical gear reducer (According to the
attached table). The gear box has an input power of 4.5 (kW), an input speed of 2500rpm
(rpm), a transmission ratio of 2.5, and a service life of 15 (kh). the pressure angle is
20
o
and the helix angle may be chosen between 20
o
and 30
o
.
Detail drawings of a similar gear-box are shown on the following pages. The
pinion can be integrated with (or mounted on) the driving shaft (5) . The gear is
mounted on the driven shaft (3) by means of a feather 6x6x15 (11). Both shafts are
supported on the casing through two ball bearings (e. g. D = 35 mm, B = 11). A
guffro sealing (e.g. D = 25 mm, B = 7 mm) is used to prevent leakage of oil from
both ends of input and output shafts. Covers are fixed to the casing of the gear box
through 4 bolts (e.g. M3x8). the upper and lower parts of the casing are fixed
together by means of ten M6x18. Also there are two positional pins 3×10 .
You are asked to submit the following documents:

a) A short technical report including your design and checking calculations.


basically i need the first part which is designing a pinion and a gear meshed together and getting me a factor of safety for bending stress between 2.5 to 4~ and a factor of safety for contact stress between 1.2 to 1.4 Im stuck and i thought i could ask for help.

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