FOUR SPEED SLIDING MESH GEAR BOX

BY M.ATHITHAKARIKALAN

A.MANIKANTA REDDY
C.CHARAN P.G DHINESH KHANNA

GEAR BOX
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

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 give different speeds and torques. To provide high torque at the time of starting, vehicle acceleration, climbing. To drive vehicle at low speeds

TYPES OF GEAR BOX

1. Manual transmission (a) Sliding mesh Gear box (b) Constant mesh Gearbox (c) Synchromesh Gearbox 2. Epicyclic Gear box 3. Automatic Gearbox (a) Hydromatic Gearbox (b) Torque converter Gearbox

GEAR RATIO
The slowest gears (designated '1' or low gear) in most automotive applications allow for three to four engine rotations for each output revolution (3:1).

"High" gear in a three or four speed manual transmission allows the output shaft to spin at the same speed as the engine (1:1). Five and six speeds are often 'overdrive' with the engine turning less than a full turn for each revolution of the output shaft (0.8:1, for example) When two gear have same number of teeth, they rotate at the same speed. The gear ratio is 1:1. But if one gear has 10 teeth and the other with 20 teeth the gear ratio is 2:1 .This is considerably because the smaller gear has to rotate twice more than the larger gear .If the smaller gear which has the 10 teeth and the larger gear 30 teeth, the gear ratio is 3:1.

Speed ratio =

PARTS OF COMMON GEAR BOX

Clutch
Main shaft Lay shaft Selector fork Reverse gear Idle shaft Sleeve Casing or housing Bearings Primary shaft.

Dog clutch

Gear shifting lever

COMPONENTS USED IN GEAR BOX

DRIVESHAFT
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: 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:
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 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

DESIGN CALCULATION OF GEAR BOX

DESIGN ASSUMPTIONS : Power : 3 KW Speed (N) : 750 rpm Speed ratio : 2 STEP-1: TO FIND THE GEAR SPEEDS: GEAR RATIO =2 (assumed)
1 2

=2

2 = 375 RPM

STEP 3:
INITIAL DESIGN TORQUE: [ ] = . K . =
97420.3 = 750

389.68

ASSUMING,

K . = 1.3
[ ] = 50.6 X 103 STEP 4:

TO FIND BENDING AND CRUSHING STRESSES:

FROM DESIGN DATA BOOK, BENDING STRESS: 140 CRUSHING STRESS: 500
2 2

STEP 5: TO FIND THE MINIMUM CENTRE DISTANCE: + 1

0.74 2 2

, = 0.3 88
STEP 6: 1.26
3

ASSUME, =10; 1 = 10, 2 = 20 AND Y = 0.3890 3

STEP 7 TO FIND THE MINIMUM MODULE 1 = 33 2 = 22 STEP 8 TO FIND THE PITCH CIRCLE DIAMETER

1 = 52.5 mm
2 = 36 mm. STEP 9 TO FIND THE ACTUAL CENTER DISTANCE a = m.
1 + 2 2

= 83.

Initial centre distance is less than actual centre distance. So, the design is feasible.

STEP -10
TO FIND THE FACE WIDTH =

= 0.3(83) b= 25 mm STEP 11 TO FIND THE ACTUAL DESIGN TORQUE [ ] = [ ]. k.

1 25 40

= 0.6
1

From design data book for V=

1 1 60 1000

the corresponding k value is 1.06

= 1.143

From design data book, for velocity 1.143m/s the corresponding = 1.3 . Therefore the actual design torque [Mt] (actual) = 50.6 X 103 N.mm

STEP 11: TO CHECK THE INDUCED STRESSES:

Crushing stress = .74

1 ( )

= 92.5 2 The Crushing stress is less than the assumed crushing stress and so the design is safe.
1

Bending stress =

= 68.8

The Bending stress is less than the assumed bending stress and so the design is safe

STEP- 13 TO FIND THE OTHER DIMENSIONS Take (0 ) = 1 BOTTOM CLEARENCE C =0.25 (m) = 0.25 (3) = 0.75 mm TIP DIAMETER 1 = (1 + 20 ) m = 72. 2 = (2 + 2 0 ) m = 75 mm ROOT DIAMETER 1 = (1 - 20 ) m

= 60 mm
1 = (2 - 20 ) m = 93 mm.

DESIGN CALCULATION FOR SHAFT, KEY: FOR SHAFT: = 50.6 X 103 =

16 16

3 3 = 140
2

160 ) 2

F.O.S = 2 (assumed)

D = 14.76 mm So we turned shaft for 15 mm diameter.

FOR KEY: For the calculated diameter the size of key choosen is 6mm X 3mm X 100mm.