SSRG International Journal of Mechanical Engineering (SSRG-IJME) volume 2 Issue 6June 2015

Design and Study of Four Speed Sliding Mesh Gear Box

Atthuru Manikanta Reddy1, Aakash.k2
12

Department of Mechanical Engineering, R.M.K. Engineering college, Anna University, Chennai, India

ABSTRACT: This Paper deals with understanding

of the gear transmission system principles with its
design and working. Different types of gears are
used in automobiles. Gears have teeth which mesh
with each other to transmit the drive. A detailed
CAD(Computer-aided design) model has also been
developed according to the theoretical calculations
to validate the design and an brief study of the four
speed sliding mesh gear box.
Keywords -Gear Transmission, Meshing, CAD,
Drive and Automobiles
I.INTRODUCTION
Gearbox is enclosed system of assembled gears that
transmits mechanical energy from a prime mover to
an output device. A gearbox can also change the
speed, direction, or torque of mechanical energy.
Gear box is a device placed between the clutch and
propeller shaft. It allows the engine to run at
different speeds relative to road vehicles, so as to
maintain its power and regulates the torque. The
vehicle requires high torque when climbing hills
and when starting, even though they are performed
at low speeds .On the other hand, when the vehicles
are running at high speeds on the road level, high
torque is not required because of momentum.
PURPOSE OF GEAR BOX
An automobile is able to provide varying speed
and torque through its gear box. Various functions
of a gear box are listed below To provide high
torque at the time of starting, vehicle acceleration,
climbing.To provide more forward speeds by
providing more than one gear ratios. In modern
cars, four to five forward gears and reverse gear is
provided. For given engine speed, higher speed can
be obtained by running in higher (4th and 5th)
gears.To provide a reverse gear for driving the
vehicle in reverse direction and To give different
speeds and torques. To get high acceleration from
rest .To drive vehicle at low speeds. In the engine
running conditions the vehicle can be stopped by
changing the gear to neutral condition without
applying brake.

II. WORKING PRINCIPLE OF SLIDING

MESH GEARBOX
It is simplest type of gear box out of the available
gear boxes. In this type of gear box, gears are
changed by sliding one gear on the other. This gear
box consists of three shafts; main shaft, clutch shaft

ISSN: 2348 8360

and a counter shaft. In a four speed gear box

(which includes one reverse gear), the counter shaft
has four gears which are rigidly connected to it.
Clutch shaft has one gear and main shaft has two
gears. The two gears on the main shaft can slide in
the horizontal direction along the splines of the
main shaft. However, the gears on the counter shaft
cannot slide. The clutch gear is rigidly fixed to the
clutch shaft. It is always connected to the counter
shaft drive gear.
The two gears on the main shaft can be slide
by the shifter yoke by operating the shift lever (not
shown in Figures). These two gears are second gear
and low/reverse gear respectively. These gears can
be meshed with corresponding gears on the counter
shaft with the help of shifter yoke and shift lever.
Shift lever is operated by hand in four wheelers for
changing the gears. A reverse idler gear is mounted
on another (third) shaft and is always in mesh with
reverse gear on counter shaft.
Neutral position:
The above figure shows sliding mesh gear box
in neutral position. In this position, the engine is in
running condition, clutch remains engaged and
clutch gear drives the counter shaft drive gear. The
direction of rotation of countershaft is opposite to
that of clutch shaft. In this position Ist, IInd and
IIIrd and reverse gears are free. Thus, main
(transmission) shaft does not rotate and automobile
wheels do not rotate. So vehicle remains stationary

First Gear:
When first gear position is selected by the
shift lever, first gear (large gear) on the main shaft
slides and is connected to first gear on the
countershaft. The direction of rotation of main

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SSRG International Journal of Mechanical Engineering (SSRG-IJME) volume 2 Issue 6June 2015
shaft is same as that of clutch shaft. In first gear,
small gear of counter shaft meshes with larger gear
on main shaft, speed reduction in the ratio 3: 1
(approximate) is obtained.
Second Gear:
When second gear is selected by the shift
lever, second gear on counter shaft meshes with
second gear (small gear on main shaft) on the main
shaft. The direction of main shaft is same as that of
clutch shaft. Speed reduction of the order of 2: 1 is
obtained in second gear.

A drive shaft is a mechanical component for

transmitting torque and rotation, usually used to
connect other components of a drive train that
cannot be connected directly because of distance or
the need to allow for relative movement between
them. Drive shafts are carriers of torque: they are
subject to torsion and shear stress, equivalent to the
difference between the input torque and the load.
They must therefore be strong enough to bear the
stress, whilst avoiding too much additional Weight
as that would in turn increase their inertia.
Bearings:

Third Gear
In third gear, the main shaft is slides axially
towards the clutch shaft so that main shaft is
directly connected to the clutch shaft. In this
position, the main shaft rotates at the speed of
clutch shaft. Thus, a speed ratio of 1: 1 is obtained.
It can be noted that the clutch gear is directly
connected to engine crankshaft and main shaft is
connected to the wheels through propeller shaft.
Reverse Gear

Fig 2.2 Bearings

When the shift lever is operated to engage the

reverse gear, the larger (reverse) gear of the main
shaft meshes with the reverse idler gear. Reverse
idler gear is always connected to reverse gear on
counter shaft. The reverse idler gear between
counter shaft reverse gear and main shaft larger
gear changes the direction of rotation of main shaft.
Thus, the direction of main shaft becomes opposite
to that of clutch shaft. Therefore, wheels of the
automobile start moving in backward direction.
(Note: Countershaft is also known as lay shaft.)

III . COMPONENTS USED IN GEAR BOX

Some of the components used in gear box are:

Bearings are highly engineered, precision-made

components that enable machinery to move at
extremely high speeds and carry remarkable loads
with ease and efficiency. It must be able to offer
high precision, reliability and durability, as well as
the ability to rotate at high speeds with minimal
noise and vibration. Bearings are found in
applications ranging from automobiles, airplanes,
computers, construction equipment, machine tools,
DVD players, refrigerators and ceiling fans. If
something twists, turns or moves, it probably has a
bearing in it.

Selector fork:

Shaft
Bearing
Selector Forks

Shafts:

Fig 2.3 Selector Fork

Fig 2.1 Drive Shaft

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The shifter fork and fork rods have a

mechanism using a plunger with a ball in it and is
supported with a slide able ball bearing. The detent
mechanisms give the driver distinctive detent

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SSRG International Journal of Mechanical Engineering (SSRG-IJME) volume 2 Issue 6June 2015
feeling and the sliding ball bearings help reduce the
shift lever operating force. All shifter forks are
made of aluminium die casting and the shifter arm
shaft is formed as a hollow type to minimize the
overall weight of the transmission. Gear double
meshing is prevented by a mechanism that uses
interlock blocks. The select return mechanism
(which returns the selector lever to the neutral
position) uses a U shaped leaf spring.

(i+1)

Assume,

= 0.3

88 mm.

STEP -6
TO FIND THE MODULE
m

1.26

IV . DESIGN CALCULATION OF GEAR BOX

For design calculation of the spur gear,
Power

: 3kw

Speed (N)

: 750 rpm

Speed ratio

:2

Assume,
y = 0.3890
m

=10;

= 10;

= 20 and

STEP 7
TO FIND THE NUMBER OF TEETH

STEP-1
TO FIND THE GEAR RATIO:

= 33
i =2 (assumed); Hence,

= 2;

= 22
STEP 8
TO FIND THE PITCH CIRCLE DIAMETER

= 375 rpm
STEP-2
TO SELECT THE MATERIAL

= 52.5 mm

For gear and pinion, let us select the

same material. i.e., C45 (STEEL)

STEP 9
TO
FIND
DISTANCE

STEP-3
INITIAL DESIGN TORQUE
[
[

]=[

Assume, k.
[

]. k.

]=

= 36 mm.

a = m.

= 389.68 kgf.cm

CENTER

= 83.

So, the design is feasible.

N.mm

STEP -4
TO FIND BENDING AND CRUSHING
SRESSES

STEP -10
TO FIND THE FACE WIDTH
=

FROM DESIGN DATA BOOK

= 0.3(83)
b= 25 mm

Bending stress: 140

STEP 11
TO FIND THE ACTUAL DESIGN TORQUE

Crushing stress: 500

STEP-5
TO FIND MINUIMUM CENTRE DISTANCE

ISSN: 2348 8360

ACTUAL

Initial centre distance is less than

actual centre distance.

=1.3;

] = 50.6 X

THE

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]=[

]. k.

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SSRG International Journal of Mechanical Engineering (SSRG-IJME) volume 2 Issue 6June 2015
= 72mm

=(

+2

)m

= 0.6
= 75 mm
From design data book for

, k=1.06

ROOT DIAMETER
=(

V=

-2

)m

= 60 mm
V= 1.143
=(

-2

)m

From design data book, for velocity 1.143m/s the

corresponding

= 93 mm.

= 1.3

Therefore the actual design torque [Mt] (actual) =

50.6 X

STEP-14:
DESIGN CALCULATION FOR SHAFT, KEY

N.mm

STEP- 12:
TO CHECK THE INDUCED STRESSES:

Crushing stress =

FOR SHAFT

50.6 X

;[

= 140

; F.O.S = 2 (assumed)]

= 92.5
The Crushing stress is less than the assumed
crushing stress and so the design is safe.

D = 14.76 mm
D (Std) = 15 mm diameter.
FOR KEY

Bending stress =

For the calculated diameter the size of key chosen

is 6mm X 3mm X 100mm.
= 68.8
CAD MODELLING PHOTOGRAPHY:
The Bending stress is less than the assumed
bending stress and so the design is safe
STEP- 13:
TO FIND THE OTHER DIMENSIONS
Take (

)=1

BOTTOM CLEARENCE
C =0.25 (m)
= 0.25 (3)
= 0.75 mm
TIP DIAMETER
=(

ISSN: 2348 8360

+2

Fig 4.1 Model diagram of Four Speed Sliding

Mesh Gear Box
)m

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SSRG International Journal of Mechanical Engineering (SSRG-IJME) volume 2 Issue 6June 2015
REFERENCES

Fig 4.2 Design of Four Speed Sliding Mesh

Gear Box
V. CONCLUSION
The aim of our paper is that we have
undertaken in our engineering course is to improve
our practical knowledge in design and fabrication
of a particular component in a technical manner.
This improves not only our practical skills, but also
our various managing functions such as planning
the project design, fabrication and erection and cost
analysis etc. This paper is planned and completed
as per the schedule and regulations. And In
addition to that, by accomplishing this project of
FOUR SPEED GEAR BOX successfully we felt
that we have obtained enough knowledge regarding
this topic, with full of satisfaction and forward the
project to concerned.

ISSN: 2348 8360

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Wei.

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