DESIGN OF GEAR BOX

prepared by
yaried worku
muket AGMAS
MAIN CONTENTS

Introduction
Background
Purpose of gearbox
Types of gearbox
Components of gearbox
Objective of gearbox
INTRODUCTION

 gear box is a device for converting the speed of a shaft from

one speed to another. In process the torque is also changed.
 A gearbox can be simple or complex and is a machine that is
used to transfer rotational energy from a motor to another
device
 They are generally used to increase the torque while
decreasing rotational speed, they do not have any effect on the
power developed by the motor because as torque increases,
rotational speed decreases and vice versa.
Background
 The first transmission system was given by
French Inventors Louis-Rene and Emile
Levassor who invented the world largest ever
transmission system with 3-speed sliding mesh
transmission in 1894.
 Gear ratio is achieved by sliding the required
gears to bring it with appropriate mating gears.
The advanced gearbox of today has reverted to
what it was back in 1928 three-speed and non-
synchromesh.
Cont’d
 A gear box, also known as a gear case or gear head, is
a gear or a hydraulic system responsible for
transmitting mechanical power from a prime mover
in to some form of useful output. It is referred to the
metal casing in which the numbers of gears are
sealed.
 A gearbox is a transmission device used between the
engine's output shaft and the final drive to transfer the
torque and power required for the vehicle's wheels,
the gearbox consists of a set of gears (i.e. spur,
helical, bevel, worm And epicycle depending on the
types of gearboxes used.
Purpose of gearbox

 Provides speed and torque conversions

 Also facilitates change of direction of output
shaft for reversing.
 Multiply (or increase) the torque (turning
effort) being transmitted by the engine
 Ensuring comfortable starting of the vehicle
 To convert the engine torque into the wheel
traction required to overcome the motion
resistance.
Type of gearbox

 Manual /Selective type

 Sliding mesh
 Constant mesh
 synchromesh
 Progressive type
 Epicyclical type
Components of gearbox

 Gears
 shafts
 Bearing
 Housing
 Key
Gear
 Gear is defined as a machine element used to transmit
motion and power between rotating shafts by means of
progressive engagement of projections called teeth.
classification of gear
 Spur gear
 Helical gear
 Herringbone gear
 Spiral bevel gear
 Hypoid gear
 Cross helical gear
Shaft
 A shaft is a rotating machine element which is
used to transmit power from one place to another.
 Shear stresses due to the transmission of torque
(i.e. due to torsional load).
 Bending stresses (tensile or compressive) due to
the forces acting upon machine element like
gears, pulleys etc.
 Stresses due to combined torsional and bending
loads
Type of shaft

 Input shaft
 Output shaft
 Counter shaft
Bearing

 A bearing is a machine element which supports another

moving machine element (known as journal).
 It permits a relative motion between the contact surfaces of the
members, while carrying the load
Classification of bearing

 Bearings may be classified as given below

 Depending upon the direction of load to be supported.
The bearing under this group are classified as
 Radial bearings
 Thrust bearings
 Depending upon the nature of contact. The bearing
under this group are classified as:
 Sliding contact bearings
 Rolling bearing
Housing

 It consists of the parts; the gear box

housing was sided from the extension
by a lover.
 The foxing point for the left
assembly braket is locating at the gear
box housing the attachment point for
self aligning of the gear box.
Problem statement
 When the gear reducer is running, the gearbox
vibration is generated. Gearboxes work on the
principle of meshing of teeth,
 Which result in the transmission of motion and
power from the input source to the output. Hence
due to continuous meshing of gear, high friction
and excessive heat introduce among the gear tooth.
 This later will create problems such as wearing of
tooth, slipping of gear, wobble effect and it may
fatigue for the driver as well as it can shortening
the lifecycle of the component.
Cont’d
 More, there may be clutch dragging, noisy
driving condition and sticking of pedal on
the clutch. Furthermore there may be
Abnormal jerking movements while
changing gears, causes crew fatigue,
strained communication, and possible
hearing damage. This may create unsafe
condition for the driver and can cause a
serious injury on both the driver and the car
Objective of the project

General objectives
The general objective of this project is to
design four speed sliding mesh gearbox with
power 3.5 KW, speed of 1000 rpm and speed
ratio 15

Specific objectives
To design each/individual components of
sliding mesh gearbox.
Cont’d

To select the appropriate material for the

components
To solve geometrical analysis of sliding
mesh gearbox
To compute force and stress analysis
To select bearing
To analyze the result
Methodology
 First the necessary design parameters are collected
 By using these data we made design analysis
 Checking the result of the stresses on different parts
of the mixer
 Redesign the components if needed
 Modifying some mechanisms
 Suggesting alternative mechanisms
The scope of this design
project
 The scope of this design project is to
design a sliding mesh type four
speed, manual transmission gear box
based on 3.5kw and @ 1000 rpm
within system component part of
gearbox.
The given specifications

 Power [kw]:- 3.5KW

 Input Speed [rpm]: 1000 rpm
 Total Gear Ratio:-15:1
 Gear design
 design and construction of the gear pair
employed, gears can change the direction of
movement and/or increase the output speed or
torque.
 To choose the type of gear we must see
velocity ratio or the peripheral velocity.
 Velocity ratios up to 8 single stage drives
are preferable though these drives may be
used for velocity ratios up to 25. Two stage
drives may use for velocity ratios up to 50
from 10beyond velocity ratio of 40 three
stage drive is preferable.
 Straight spur gear drives between parallel
shafts can be used up to 5 m/s, for greater
velocities than 5 m/s helical gears must be
used.
 For high velocity ratios helical gears are
recommended. Then determine number of stages:
Speed ratio i ≤ 8 is one stage type speed reducer
(straight spur gear may be used); two-stage speed
reducer have speed ratio between 8 and 40, greater
than 40 three-stage type speed reducer.
 Due to above standards our design of gear box is
double stage gear box with helical gear profile,
since our design have a speed ratio of 15.
 Advantages of multi-stage gearboxes:
 Wide range of ratios
 Compact design with high transmission ratios
 Combination of different gearbox types possible
 Wide range of uses
 Material selection
 The selection of a proper material, for
gear, is one of the most sections on this
design. The best material is one which
serves the desired objective at the
minimum cost.
 The following factors should be considered
while selecting the material:
1. Availability of the materials,
2. Suitability of the materials for the working
conditions in service, and
3. The cost of the materials.
4. The important properties, which determine
the utility of the material, such as physical,
chemical and mechanical properties.
 Gears can be made of all sorts of materials, including
many types of steel, brass, bronze, cast iron, ductile
iron, aluminum, powdered metals, and plastics. most
engineers worked with all of the material types
mentioned.
 It is a common practice to select a material for a
product but in the case of the gear box it has special
attention as it will decide the life, cost, weight and
over all dimensions of the product.
 In gear box special attention is required for the gear
material as they are main component the will be
manufactured and they are the one under high load due
to which they will face high wear and tear.
 Following are the four materials short listed for the
gears
 Ductile Cast Iron
 Alloy Steel
 Medium Carbon Steel
 Aluminum Alloy
 We shall now discuss some of the major properties of
the materials in the following articles.
Mechanical property evaluations

Propertie Elastic Density Hardness Fatigue Fracture

s limit Strength Toughnes
s
Ductile 23.9 440 115 26.1 20
cast iron
Alloy steel 85 487 140 36 12.7
Medium 44.2 487 120 33.2 10.9
carbon
steel
Aluminum 43.5 156 12 3.13 20
alloy
 Environmental aspects and cost evaluation

Material & Cost Enbodied CO2 foot Recyclabilit

property energy print y

Ductile cast 0.318 1.95e^3 1.7 yes

iron

Alloy steel 0.272 3.11e^3 1.93 yes

Medium 0.284 2.72e^3 1.72 yes

carbon
steel
Aluminum 1.07 2.15e^4 12.2 yes
alloy
 Cost of all four materials in mention above according toFinally, we
conclude that, From all the discussion made above it is clear that alloy
steel is the best material for the gears because it has highest value of
elastic limit, fracture toughness, hardness and fatigue loading. Along with
this it has moderate values of environmental aspects and lowest cost of
material.
 Conclusion
 This paper explains the design of sliding mesh gear box with proper
material selection and design analysis to avoid major problems or failure
which happen most frequently during this machine.
 We have designed safe and functional two stage gear box as much as
possible in order to address the problems exist on gear drives.
THANK YOU!!!!