Mechanical

Design a gearbox

Gears trade speed for torque and never give you both. Stack the ratios, then check that everything downstream can survive the torque you just created.

4 steps 6 min read 3 tools chained Build

Stack the ratios

A 1750 rpm motor through two reductions. Ratios multiply, so 3:1 followed by 3:1 is 9:1 overall — and the torque rises by the same factor that the speed falls, minus efficiency.

Input1750 rpm, 10 N·m
Two stages3:1 then 3:1
Overall9:1
Rule of thumbSpeed down is torque up by the same ratio. Efficiency losses come off the torque, never off the ratio.

Add a third stage and watch efficiency bite

Each mesh costs a couple of percent. Three stages at 97% each is not 97% — it is 0.97³, and that compounding is why long gear trains run hot.

One stage97%
Three stages≈91%
Lost asheat
Rule of thumbEfficiency multiplies through a train. Every extra mesh is another few percent turned into heat you have to get rid of.

Hold it together

All that multiplied torque has to react into a housing. Bolt torque converts a size and grade into the tightening figure that produces the clamp force — which is what actually stops a joint slipping.

M10 8.8, dry75% of yield
Lubricatedsame torque, far more tension
Rule of thumbFriction eats most of the torque you apply. Only a small share becomes bolt tension, which is why lubrication changes everything.

Check the bearings will last

Bearing life is brutally non-linear in load: roughly an inverse cube for ball bearings. Doubling the load does not halve the life, it cuts it to an eighth.

Ball bearing life∝ 1/load³
Double the load≈⅛ the life
Rule of thumbIf a bearing is marginal, reducing load beats upgrading the bearing — the cube works in your favour in both directions.

Ratio is the easy part

The ratio takes a minute. What it does to efficiency, joints and bearing life is the actual design work — and each of those tools will tell you when you have gone too far.

Reference only. Stories chain real tools — the numbers shown are worked examples, so check them against your own figures before relying on them.

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