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Design of Compound Reverted Helical Gear Train

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Ethan Moronez

Project Timeline

Nov 2025 - Nov-2025

OVERVIEW

I designed and analyzed a compound-reverted gear train with 45° helical gears that can transmit 0.4 HP at 1800 rpm in either direction, with a 15:1 gear ratio. Components, such as gears and bearings, were selected from catalogs to meet industry standards. The use of helical gears introduced challenges, such as accounting for axial loads and the effects of the helix angle on gear geometry and force transmission. Additionally, I wrote MATLAB code that plotted shear, moment, slope, and deflection along each shaft profile to identify critical locations. This was the first project I worked on that tested my understanding of GD&T standards, and initially, my part drawings for the shafts lacked a clear datum structure, making it difficult to control runout and gear alignment. To ensure that these features were met, I revisited the ASME Y14.5 principles, corrected the over-constrained tolerances, and redefined the datums. This entire learning process highlighted how neglected proper GD&T application leads to such headaches on the manufacturing side of engineering.

HighlightS

SKILLS

SOLIDWORKSMATLABGD&TFailure Analysis
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Ethan Moronez

Mechanical Engineering Student & Designer

I'm a mechanical engineering student at California Baptist University with a strong foundation in CAD design, finite element analysis, and hands-on manufacturing. Currently contributing to Formula SAE EV suspension design and biomechanical research. Passionate about solving complex engineering problems through simulation and prototyping.