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TRANSMISSION GEARBOX
A PROJECT REPORT
Submitted by
G.ARAVIND (312313114021)
Of
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
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ANNA UNIVERSITY: CHENNAI 600 025
APRIL 2016
BONAFIDE CERTIFICATE
Certified that this project report “DESIGN AND FABRICATION OF TWO SPEED
VARIABLE TRANSMISSION GEARBOX” is the bonafide work of “G.ARAVIND
(312313114021) & S.ARUN MOZHI THEVAN (3123131140)” who carried out
the project work under my supervision.
SIGNATURE SIGNATURE
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CERTIFICATE OF EVALUATION
SEMESTER: VI
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ACKNOWLEDGEMENTS
We would like to express our sincere thanks and gratitude to our college
Chairman Col Dr THIRU JEPPIAAR M.A., B.L., Ph.D., Managing Director Dr
BABU MANOHARAN M.A, BL, Ph.D. Director Mr JAIKUMAR
CHRISTHURAJAN B.E, M.B.A.
Principal Dr VADDI SESHAGIRI RAO M.E., Ph.D., F.I.E. for giving us this
opportunity to carry out this project.
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TABLE OF CONTENTS
TITLE PAGE NO
Abstract 7
1 Introduction 8
2 Literature review 9
3 Description of equipment 11
3.1 Gearbox 11
3.2 Spur gears 11
3.3 Shafts 15
3.4 D.C motor 17
4 Design and drawing 18
4.1 Calculation for gears 19
4.2 Drawing of sliding mesh gearbox 20
4.3 3D Modeling 21
5 Working principle 22
6 Merits & demerits 23
7 Applications 24
8 Material Considerations 24
9 Conclusion 27
10 Bibliography 28
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LIST OF FIGURES
1. Figure 1 11
2. Figure 2 16
3. Figure 3 20
4. Figure 4 22
5. figure 5 17
LIST OF TABLES
1 Table 1 25
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ABSTRACT
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CHAPTER I
INTRODUCTION
The main objective of our project is to create a gearbox with several inputs and
a single output. For this purpose, we have selected two input shafts and one output
shaft. It is a two speed sliding mesh gear box, controlled by a dog clutch for the
required sliding mechanism. It is simple, effective and a cost efficient design.
CHAPTER II
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LITERATURE REVIEW
TRANSMISSION
An assembly of parts including the speed-changing gears and the propeller
shaft by which the power is transmitted from an engine to a live axle. Often
transmission refers simply to the gearbox that uses gears and gear trains to
provide speed and torque conversions from a rotating power source to another
device.
The most common use is in motor vehicles, where the transmission adapts the
output of the internal combustion engine to the drive wheels. Such engines need to
operate at a relatively high rotational speed, which is inappropriate for starting,
stopping, and slower travel. The transmission reduces the higher engine speed to the
slower wheel speed, increasing torque in the process. Transmissions are also used on
pedal bicycles, fixed machines, and where different rotational speeds and torques are
adapted.
Often, a transmission has multiple gear ratios (or simply "gears"), with the
ability to switch between them as speed varies. This switching may be done manually
(by the operator), or automatically. Directional (forward and reverse) control may
also be provided. Single ratio transmissions also exist, which simply change the
speed and torque (and sometimes direction) of motor output.
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(essential to avoid wheel slippage on turns) as it changes the direction of rotation.
Most modern gearboxes are used to increase torque while reducing the speed
of a prime mover output shaft (e.g. a motor crankshaft). This means that the output
shaft of a gearbox rotates at a slower rate than the input shaft, and this reduction in
speed produces a mechanical advantage, increasing torque. A gearbox can be set up
to do the opposite and provide an increase in shaft speed with a reduction of torque.
Some of the simplest gearboxes merely change the physical rotational direction of
power transmission.
USES:
Assembly of parts including the speed changing gears and the propeller shaft
by which the power is transmitted from an engine to a live axle. Often
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transmission refers simply to the gearbox that uses gears and gear trains to
provide speed and torque conversions from a rotating power source to another
device.
CHAPTER III
DESCRIPTION OF EQUIPMENTS
3.1 GEARBOX
(Figure 1)
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Number of teeth, N
How many teeth a gear has, an integer. In the case of worms, it is the number
of thread starts that the worm has.
Gear, wheel
The larger of two interacting gears or a gear on its own.
Pinion
The smaller of two interacting gears.
Path of contact
Path followed by the point of contact between two meshing gear teeth.
Line of action, pressure line
Line along which the force between two meshing gear teeth is directed. It has
the same direction as the force vector. In general, the line of action changes
from moment to moment during the period of engagement of a pair of teeth.
For involute gears, however, the tooth-to-tooth force is always directed along
the same line—that is, the line of action is constant. This implies that for
involute gears the path of contact is also a straight line, coincident with the line
of action—as is indeed the case.
Axis
Axis of revolution of the gear; center line of the shaft.
Pitch point
Point where the line of action crosses a line joining the two gear axes.
Pitch circle, pitch line
Circle centered on and perpendicular to the axis, and passing through the pitch
point. A predefined diametric position on the gear where the circular tooth
thickness, pressure angle and helix angles are defined.
Pitch diameter, d
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A predefined diametric position on the gear where the circular tooth thickness,
pressure angle and helix angles are defined. The standard pitch diameter is a
basic dimension and cannot be measured, but is a location where other
measurements are made. Its value is based on the number of teeth, the normal
module (or normal diametric pitch), and the helix angle. It is calculated as:
where m is the module and p the circular pitch. The units of module are
customarily millimeters; an English Module is sometimes used with the units
of inches. When the diametric pitch, DP, is in English units,
where a is the axis distance, z1 and z2 are the number of cogs (teeth) for each of
the two wheels (gears). These numbers (or at least one of them) is often chosen
among primes to create an even contact between every cog of both wheels, and
thereby avoid unnecessary wear and damage. An even uniform gear wear is
achieved by ensuring the tooth counts of the two gears meshing together
are relatively prime to each other; this occurs when the greatest common
divisor (GCD) of each gear tooth count equals 1, e.g. GCD(16,25)=1; If a 1:1
gear ratio is desired a relatively prime gear may be inserted in between the two
gears; this maintains the 1:1 ratio but reverses the gear direction; a second
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relatively prime gear could also be inserted to restore the original rotational
direction while maintaining uniform wear with all 4 gears in this case.
Mechanic engineers at least in continental Europe use the module instead of
circular pitch. The module, just like the circular pitch, can be used for all types
of cogs, not just evolving based straight cogs.
Operating pitch diameters
Diameters determined from the number of teeth and the center distance at
which gears operation.
Pitch surface
In cylindrical gears, cylinder formed by projecting a pitch circle in the axial
direction. More generally, the surface formed by the sum of all the pitch
circles as one moves along the axis. For bevel gears it is a cone.
Angle of action
Angle with vertex at the gear center, one leg on the point where mating teeth
first make contact, the other leg on the point where they disengage.
Addendum
Radial distance from the pitch surface to the outermost point of the
tooth.
Dedendum
Radial distance from the depth of the tooth trough to the pitch
surface.
Whole depth
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The distance from the top of the tooth to the root; it is equal to addendum plus
dedendum or to working depth plus clearance.
Diametric pitch
D
Ratio of the number of teeth to the pitch diameter. Could be measured in teeth
per inch or teeth per centimeter, but conventionally has units of per inch of
diameter. Where the module, m, is in metric units
In English units.
3.3 SHAFTS
Shafts are rotating members that transmit power through them. They are
splined or slotted for a properly transmitting power and also acts as a coupling
medium.
(Figure 2)
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Shaft
Spur gear
SHAFT LOCK RING
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• 300 RPM at 12V D.C motor with Metal Gearbox
• 18000 RPM base motor
• 6mm shaft diameter
• Gearbox diameter: 37 mm.
• Motor Diameter: 28.5 mm
• Length 63 mm without shaft
• Shaft length 15mm
• 300gm weight
• 10kgcm torque
• No-load current = 800 mA(Max), Load current = upto 9.5
A(Max)
CHAPTER IV
DESIGN AND DRAWING
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4.1 DESIGN CALCULATIONS
Using Buckingham’s and Lewis Equations:
1) Selection of Material:
Gears, pinion and shafts are made of mild steel.
2) Calculation of Transmissibility Ratio:
I = (Z2/Z1) = (30/20) = 1.5
3) Calculation of tangential load:
Ft = (K0*103*W) / Vm
K0 = 1.5 (for median life)
= (1.5*750)/Vm
Vm = (П d1N1)/60 = (ПmZ1N1)/ (60*1000)
= (П*m*20*300)/ (60*1000)
Vm = 0.314m
Which implies,
Ft = (1.5*750)/Vm
= (3582.8)/m
4) Calculation of initial dynamic load:
Fd = Ft * Cv
Cv = (6 + Vm)/ 6 = 3 (Assume Vm = 12)
Fd = (3*3582.8)/m = 10748.4/m
5) Calculation of Beam Strength:
b= 10m
FB= [σb] by*Pa = 720*10*m*y*П*m
Y=0.1084
FB = 2450.70 m2
6) Calculation of module:
2450.70m2 = (10748.4)/m
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m= 1.6 ᴝ 2mm (standard)
7) Revaluation of Beam strength:
FB = 98028 N
Ft = 1791.4 N
8) Calculation of Dynamic load:
Vm = 0.628mm
d1 = mZ1
= 2*20= 40mm
Fd = 1796.17 N
Fs > Fd (Hence design is safe)
Fw = d1*Q*Kb
= 20*1.2*1.1*20
= 528 N
Q = 2(1.5)/ (1.5+1) = 1.2
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(Figure 3)
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3-D MODELLING
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IMAGES ATTACHED
(figure4)
CHAPTER V
WORKING PRINCIPLE
The spur gears in the gearbox having same pitch mesh against each other. The speed
and torque produced depend upon the gear ratios. The input power of the gearbox is
usually constant, thus the output power too is constant.
The gear ratios are changed by changing the gears using a gear shifting mechanism
by the use of a dog clutch. The dog clutch is connected to a handle or knob for the
gear selection.
CHAPTER VI
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MERITS & DEMERITS
MERITS
Quicker operation.
Easy transmission.
Low cost machine.
It is used for carrying out multiple operations in a single machine.
Both Forward and reverse speeds can be obtained
DEMERITS
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CHAPTER VII
APPLICATIONS
CHAPTER VIII
MATERIAL CONSIDERATIONS
1. Properties:
The material selected must posses the necessary properties for the proposed
application. The various requirements to be satisfied
Can be weight, surface finish, rigidity, ability to withstand environmental attack
from chemicals, service life, reliability etc.
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their selection
a. Physical
b. Mechanical
c. From manufacturing point of view
d. Chemical
The various physical properties concerned are melting point, thermal
Conductivity, specific heat, coefficient of thermal expansion, specific gravity,
electrical conductivity, magnetic purposes etc.
The various Mechanical properties Concerned are strength in tensile,
Compressive shear, bending, torsional and buckling load, fatigue resistance, impact
resistance, eleastic limit, endurance limit, and modulus of elasticity, hardness, wear
resistance and sliding properties.
The various properties concerned from the manufacturing point of view are,
Cast ability
Weld ability
Surface properties
Shrinkage
Deep drawing etc.
2. MANUFACTURING COST:
Sometimes the demand for lowest possible manufacturing cost or surface qualities
obtainable by the application of suitable coating substances may demand the use of
special materials.
3. QUALITY REQUIRED:
This generally affects the manufacturing process and ultimately the material.
For example, it would never be desirable to go casting of a less number of
components which can be fabricated much more economically by welding or hand
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forging the steel.
4. AVAILABILITY OF MATERIAL:
Some materials may be scarce or in short supply; it then becomes obligatory
for the designer to use some other material which may not be a perfect substitute for
the material designed. The delivery of materials and the delivery date of product
should also be kept in mind.
5. SPACE CONSIDERATION:
Sometimes high strength materials have to be selected because the forces involved
are high. In such cases it is of extreme importance to ensure that the space
optimization is not compromised on in the venture to impart high strength and
rigidity.
6. COST:
Factors like scrap utilization, appearance, and non-maintenance of the
designed part are involved in the selection of proper materials.
(Table 1)
CHAPTER IX
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CONCLUSION
This project is made with pre planning, that it provides flexibility in operation.
Smoother and easy handling operation by the principle of “Gear Mechanics”
The comparative gain that can be accomplished is the utilization of roller bar.
This innovation has made the more desirable
This project “Design and fabrication of Hybrid Gearbox” is designed with the
hope that it is very much economical and help full to many industries and workshops
This project helped us to know the periodic steps in completing a project work.
Thus we have completed the project successfully.
BIBLIOGRAPHY
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1. Design data book -P.S.G.Tech.
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