Capital University of Science and Technology

Islamabad
CAD-CAM PROJECT REPORT
Manual Gearbox Design Using PTC Creo
and Analysis Using Ansys
By:

Rana M Jahanzaib

ME-123079

Usama Bilal

ME-123097

Khalid Munir Hashmi

ME-123078

Submitted To:
Dated:

Sir Abdul Wahab

Jan 08,2016

Copyright

2016 by CUST Student

All rights reserved. Reproduction in whole or in part in any form requires the prior
written permission of Rana M Jahanzaib, Usama Bilal, Khalid Munir hashmi or
designated representative.

A Project Report submitted to the

DEPARTMENT OF MECHANICAL ENGINEERING
in partial fulfillment of the requirements for the Lab project of
CAD/CAM
Faculty of Engineering
Capital University of Science and Technology
Islamabad
Jan 08, 2016

Problem Overview:
The objective of this project is to design, and analyze an efficient four
speed manual transmission. Efficiency will be based on speed and
torque, Gear ratios will be calculated to determine the most efficient
transmission. A manual transmission is a transmission commonly used
in motor vehicle applications. Manual Transmissions have been around
since the invention of the car and were the most common transmission
until the introduction of the automatic transmission in 1938. Although
less common, manual transmissions are still produced and are seen
commonly in sports cars. The design will be followed by the
calculations of gear ratios and gear specifications, using concepts and
ideas researched beforehand about transmissions. The CAD program
Creo will then be used to make a computer model of the gearbox, and
at the end the designed model will be analyzed on ansys for the total
deformation of gears, equivalent stresses on the shaft and the elastic
strain on the shaft. The transmission has an ingoing shaft connected
directly to the motor. The gear on the incoming shaft is connected to
the lay-shaft. The lay-shaft has many gears which mesh with the gears
on the outgoing shaft. A shifting gear, connected to a stick shift, moves
between gears to select different gear combinations. Depending on
which gear is meshed with the shifting gear, the output shaft, which is
connected to the differentiable, turns at the desired speed. The
transmission will be designed to optimize efficiency in terms of speed
and power (torque). Applying this transmission towards general
automotive use will make the gearing lean more towards speed rather
than torque, since a large amount of low-end torque is not necessary
for automobiles.

Design Goal:

The purpose of designing and creating a two or four speed

transmission is to find the most efficient way to optimize power and
speed using the input of the transmission. A four speed transmission
has been decided on that will be used for general automobile
purposes. This means that the gearing will be created to favor higher
gear ratios and thus sacrifice power and torque for general speed and
more efficient use of the engines RPM. Gear ratios in first gear will
start around 3:1 (Engine : Drive shaft), around 2:1 in second gear, 1:1
in third gear, and fourth gear will serve as an overdrive with an
approximate 0.8:1 ratio. This will make both third and fourth gear very
efficient in converting the engines RPMs into speed at the drive shaft.

Top View

DESIGN SPECIFICATIONS:
Motor: 5 hp, with 1800 rpm

Spur Gear:
The simplest mean of transferring rotary motion from one shaft to another
shaft is by using a gear train. It consists of its own set of gear ratios that the
gears have on each shaft. Spur gears are the most common type of gears.
They have straight teeth, and are mounted on parallel shafts.
In our design of the gear box the gear ratio was:
Gear ratio in first gear: 3:1 (engine: drive shaft)
Gear ratio in second gear: 2:1
Gear ratio in third gear: 1:1
Gear ratio in fourth(overdrive gear): 0.8:1

Engine RPM:

= 1800 rpm

Pressure Angle (): 14.5

Diametral pitch (Pd): 32

Light Blue (48 teeth):

- Pitch Diameter (dp) =

N
Pd

= 48/32 = 1.5"

- Base Circle Diameter (db) = dp * cos() = 1.5" * cos(14.5) = 1.452"

- Addendum (a) =

- Dedendum (b) =

1
Pd

= 1/32 = 0.03125"

1.157
= 0.0362"
Pd

- Outside Diameter (Do) = Pd + 2*a = 1.5" + 2*0.03125" = 1.5625"

- Root Diameter (DR) = Pd - 2*d = 1.5" - 2*0.0362" = 1.4276"

- Gear Tooth Spacing (GT) =

360
N

= 360/48 = 7.5 degrees

Purple: (40 teeth)

- Pitch Diameter (dp) =

N
Pd

= 40/32 = 1.125"

- Base Circle Diameter (db) = dp * cos() = 1.125" * cos(14.5) = 1.0891"

- Addendum (a) =

- Dedendum (b) =

1
Pd

= 1/32 = 0.03125"

1.157
= 0.0362"
Pd

- Outside Diameter (Do) = Pd + 2*a = 1.125" + 2*0.03125" = 1.1875"

- Root Diameter (DR) = dp - 2*b = 1.125" - 2*0.0362" = 1.0526"

- Gear Tooth Spacing (GT) =

360
N

= 360/40 = 9 degrees

Green: (16 teeth)

- Pitch Diameter (dp) =

N
Pd

= 40/32 = 0.5"

- Base Circle Diameter (db) = dp * cos() = 0.5" * cos(14.5) = 0.4840"

- Addendum (a) =

- Dedendum (b) =

1
Pd

= 1/32 = 0.03125"

1.157
= 0.0362"
Pd

- Outside Diameter (Do) = Pd + 2*a = 0.5" + 2*0.03125" = 0.5625"

- Root Diameter (DR) = dp - 2*b = 0.5" - 2*0.0362" = 0.4276"

- Gear Tooth Spacing (GT) =

360
N

= 360/16 = 22.5 degrees

Red: (32 teeth)

- Pitch Diameter (dp) =

N
Pd

= 40/32 = 1"

- Base Circle Diameter (db) = dp * cos() = 1" * cos(14.5) = .9681"

- Addendum (a) =

- Dedendum (b) =

1
Pd

= 1/32 = 0.03125"

1.157
= 0.0362"
Pd

- Outside Diameter (Do) = Pd + 2*a = 1" + 2*0.03125" = 1.0625"

- - Root Diameter (DR) = dp - 2*b = 1" - 2*0.0362" = 0.9276"

- Gear Tooth Spacing (GT) =

360
N

= 360/32 = 11.25 degrees

Dark Blue: (24 teeth)

- Pitch Diameter (dp) =

N
Pd

= 40/32 = 0.75"

- Base Circle Diameter (db) = dp * cos() = 0.75" * cos(14.5) = 0.7261"

- Addendum (a) =

- Dedendum (b) =

1
Pd

= 1/32 = 0.03125"

1.157
= 0.0362"
Pd

- Outside Diameter (Do) = Pd + 2*a = 0.75" + 2*0.03125" = 0.8125"

- Root Diameter (DR) = dp - 2*b = 0.75" - 2*0.0362" = 0.6776"

- Gear Tooth Spacing (GT) =

360
N

= 360/24 = 15 degrees

Modeling of our Project:

It involves five involute profile spur gears, a rectangular frame and a
shaft.

Involute Spur Gears:

To make gears, all the gears have same following steps:

Steps:

Open New file, select type Part, name the file spur_gear, check use default
template and click ok

Sketch four circles and set their diameter values to be d (pitch circle diameter), od
(outer diameter), rd (root circle diameter) and bd (base circle diameter) and click

ok of sketch
Go to Model bar, click DatumCurvesCurve from equation
Add the Equations
o r=bd/2
o ang=t*90
o s=(3.1416*r*t)/2
o xc=r*cos(ang)
o yc=r*sin(ang)
o x=xc+(s*sin(ang))
o y=yc-(s*cos(ang))
o z=0
Click ok and select your reference to Default Coordinate System that will make

the involute curve and click ok.

On Model bar, click datum points and make points on origin and on pitch circle

where

involute

curve

is

touching

the

circle

and

join

them

with

DatumCurveCurve through points.

Click Copy then Paste SpecialApply move/rotate transformations to copies then

click ok then click rotate then select edge to z-axis and set angle to be 360/2xno.
of teeth(N) = k and click ok. It will create the involute curve at angle k to the
original curve.

Make datum Point on the new curve on pitch circle where involute curve is
touching the pitch circle and join it with origin through DatumCurveCurve

through points.
Create axis alongside with z-axis on origin and create plane choose that new axis

and the curve through points of second involute curve.

Click involute curve, select mirror then select our new made plane and click ok

Extrude your pitch circle up to your desired thickness

Select Sketch then select front plane then select project and
select the curves which make the gear teeth and delete all other

unnecessary segments then click ok then extrude it to required

thickness

Click Pattern and switch the first option to axis and choose z-axis
then put no. of teeth in next box and select angle to be 360and
click ok it will make the required teeth on your gear

Make a hole in a center of gear for the shaft.

Gear 1:

N= 48
d=1.5"
bd=1.452"
od=1.5625"
rd=1.4276"
tooth angle = 7.5

Gear 2:

N= 40
d=1.125"
bd=1.0891"
od=1.1875"
rd=1.0526"
tooth angle = 9

Gear 3:

N= 16
d=0.5"
bd=0.4840"
od=0.5625"
rd=0.4276"
tooth angle = 22.5

Gear 4:

N= 32
d=1"
bd=0.9681"
od=1.0625"
rd=0.9276"
tooth angle = 11.25

Gear 5:

N= 24
d=0.75"
bd=0.7261"
od=0.8125"
rd=0.6776"
tooth angle = 15

Rectangular Frame:
Steps:

Sketch a rectangle on Front Plane having Area = 4"x3.8".

Make three circle on it, first one will be on origin.
Second one is on left of first and have center to center distance

of 0.97"
Second one is on right of first and have center to center distance

of 0.95"
Diameter of Each circle is 0.19".
Extrude it to 0.19".

Shaft:
Steps:

Sketch a circle of diameter 0.19" on front plane.

Extrude it to the length of 3.785".

Assembly:

After generating all the parts of gearbox separately, we assembled

them in a single file as shown:

ANALYSIS ON ANSYS
At the end, we applied static structural analysis on our model on ansys for the total
deformation of gear, equivalent stress on shaft and the elastic strain on the shaft. The
procedure is as follow:

We defined the walls of the gear box as a fixed support

Then we applied the pressure on gear

And analyzed the gears for the total deformation

Applied equivalent (von-Mises) stress analysis on the shaft

And then the Equivalent elastic strain analysis of the shaft

CONCLUSION
In conclusion, PTC Creo Parametric provides a significant level of capability to support
engineers/designers to design and document frameworks and deliver productivity boost over
using standard modeling techniques. In this project we applied the knowledge and skills we
learned in this course and made improvement by the practical implementation of our intuitions.
PTC Creo provides a patient platform to design a model and using ansys we can analyze the
model, we can compare the analytical solution with the analyzed values to strengthen our
results and findings. In this way we can reduce the production cost by analyzing model before
production.