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FOUR SPEED SLIDING MESH GEAR BOX

BY M.ATHITHAKARIKALAN

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

direction.GEAR BOX • Gearbox is enclosed system of assembled gears that transmits mechanical energy from a prime mover to an output device. when the vehicles are running at high speeds on the road level. • On the other hand. even though they are performed at low speeds . A gearbox can also change the speed. high torque is not required because of momentum. so as to maintain its power and regulates the torque. • The vehicle requires high torque when climbing hills and when starting. 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.

• To drive vehicle at low speeds . vehicle acceleration. higher speed can be obtained by running in higher (4th and 5th) gears. climbing. • To give different speeds and torques.PURPOSE OF GEAR BOX • To provide more forward speeds by providing more than one gear ratios. four to five forward gears and reverse gear is provided. In modern cars. • To provide high torque at the time of starting. For given engine speed.

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

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 .If the smaller gear which has the 10 teeth and the larger gear 30 teeth. • Speed ratio = = .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). they rotate at the same speed.8:1. • "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). the gear ratio is 3:1. Five and six speeds are often 'overdrive' with the engine turning less than a full turn for each revolution of the output shaft (0.This is considerably because the smaller gear has to rotate twice more than the larger gear . for example) • When two gear have same number of teeth.

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 .

equivalent to the difference between the input torque and the load. . 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. whilst avoiding too much additional Weight as that would in turn increase their inertia. They must therefore be strong enough to bear the stress.COMPONENTS USED IN GEAR BOX DRIVESHAFT • A drive shaft is a mechanical component for transmitting torque and rotation. • Drive shafts are carriers of torque: they are subject to torsion and shear stress.

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

The select return mechanism (which returns the selector lever to the neutral position) uses a U shaped leaf spring . • 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.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. • Gear double meshing is prevented by a mechanism that uses interlock blocks.

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 .

3 [ ] = 50. = 97420.68 ASSUMING. K .3 = 750 389. = 1.6 X 103 STEP 4: TO FIND BENDING AND CRUSHING STRESSES: FROM DESIGN DATA BOOK. K . BENDING STRESS: 140 CRUSHING STRESS: 500 2 2 .STEP 3: INITIAL DESIGN TORQUE: [ ] = .

3 ≥ 88 STEP 6: ≤ 1. = 0. =10.STEP 5: TO FIND THE MINIMUM CENTRE DISTANCE: ≥ + 1 0.74 2 2 . 2 = 20 AND Y = 0.26 3 1 ASSUME.3890 ≤ 3 . 1 = 10.

5 mm 2 = 36 mm. 1 + 2 2 = 83. Initial centre distance is less than actual centre distance. . So.STEP – 7 TO FIND THE MINIMUM MODULE 1 = 33 2 = 22 STEP – 8 TO FIND THE PITCH CIRCLE DIAMETER 1 = 52. the design is feasible. STEP – 9 TO FIND THE ACTUAL CENTER DISTANCE a = m.

3(83) b= 25 mm STEP – 11 TO FIND THE ACTUAL DESIGN TORQUE [ ] = [ ].3 . k. Therefore the actual design torque [Mt] (actual) = 50.143 From design data book. for velocity 1. 1 25 40 = = 0.STEP -10 TO FIND THE FACE WIDTH = = 0.6 1 From design data book for V= 1 1 60 1000 the corresponding k value is 1.143m/s the corresponding = 1.6 X 103 N.06 = 1.mm .

5 2 The Crushing stress is less than the assumed crushing stress and so the design is safe.8 2 The Bending stress is less than the assumed bending stress and so the design is safe .STEP 11: TO CHECK THE INDUCED STRESSES: Crushing stress = .74 ±1 ±1 ( ) = 92. ±1 Bending stress = = 68.

20 ) m = 93 mm. .STEP.25 (m) = 0.20 ) m = 60 mm 1 = (2 .13 TO FIND THE OTHER DIMENSIONS Take (0 ) = 1 BOTTOM CLEARENCE C =0. 2 = (2 + 2 0 ) m = 75 mm ROOT DIAMETER 1 = (1 .75 mm TIP DIAMETER 1 = (1 + 20 ) m = 72.25 (3) = 0.

6 X 103 = 16 16 3 3 = 140 2 ( 160 ) 2 .S = 2 (assumed) D = 14. F. .O. KEY: FOR SHAFT: = 50. FOR KEY: For the calculated diameter the size of key choosen is 6mm X 3mm X 100mm.DESIGN CALCULATION FOR SHAFT.76 mm So we turned shaft for 15 mm diameter.