Design and Fabrication of GearBox

26/11/2009

Department of Mechanical and Automobile Engineering,

Institute of Technology and Management, Gurgaon

AIM: To design and fabricate a automobile gearbox

Objectives To design a Helical gear box Study of various gear manufacturing processes Fabrication of gear box

26/11/2009

Department of Mechanical and Automobile Engineering,

Institute of Technology and Management, Gurgaon

Representation of Gearbox

Motor

Gear box

Gear

26/11/2009

Department of Mechanical and Automobile Engineering,

Institute of Technology and Management, Gurgaon

Market Survey
Market research was done at following places regarding type and cost calculation of the Gearbox. Sokhi heli-wom gears pvt.ltd in Ghaziabad Hi-tech gears in Manesar Junk market in Mayapuri
26/11/2009
Department of Mechanical and Automobile Engineering,
Institute of Technology and Management, Gurgaon

Gearbox
A transmission or gearbox provides speed and torq ue conversions from a rotating power source to another device using gear ratios, including for a motor vehicle partly because of the limitations of internal combustion engines. Torque converters, hydraulics, electrical power and hybrid configurations may also be used for the same purpose.
26/11/2009
Department of Mechanical and Automobile Engineering,
Institute of Technology and Management, Gurgaon

Gearbox has different uses at different places. In Automobiles, engine speed is about 5000 rpm ,but wheels rotate at 1000 rpm.Machine tool spindle rotates at 50 rpm while the motor is at 1440 rpm. Automobile gearbox can have variable output and input speeds ,and few reduction ratios in between.
Department of Mechanical and Automobile Engineering,
Institute of Technology and Management, Gurgaon

Uses of Gearbox

26/11/2009

Gearbox types
It can be classified as Manual Automatic Manual Gearbox can be further divided as 1. Synchromesh and Non Synchromesh Non synchromesh includes :sliding mesh type

26/11/2009

Department of Mechanical and Automobile Engineering,

Institute of Technology and Management, Gurgaon

Synchromesh GearBox
Constant Mesh Gearbox where diagonal cut helical gear sets are constantly "meshed" together, and a dog clutch is used for changing gears. On synchromesh boxes, friction cones or "synchro-rings" are used in addition to the dog clutch. This type of gearbox is used in modern cars and trucks these days.
26/11/2009
Department of Mechanical and Automobile Engineering,
Institute of Technology and Management, Gurgaon

Material Selection
Keeping in mind cost effectiveness. It was intended to design a general purpose Gearbox, where cheaper materials would be used. So, Plain Carbon Steel will be used for moving components and Cast iron for Frames and bodies ,because of intricate shape they can be easily casted.
26/11/2009
Department of Mechanical and Automobile Engineering,
Institute of Technology and Management, Gurgaon

Materials contd.
Plain Carbon Steel with 0.4% carbon or EN8 material is selcted for shaft. Further,Hot rolled being cheaper than cold rolled and heat treated materials , hot rolled will be selcted. For gears : 30 Ni 4 Cr 1 is selected with Sut=1500Mpa For gears, additonal cheap alloying element,such as manganese (0.87%),to make it Strong , giving ultimate strength of 600 Mpa.(P.S.G Design data book 1.13)
26/11/2009
Department of Mechanical and Automobile Engineering,
Institute of Technology and Management, Gurgaon

Automatic Gearbox
This type of transmission are easy to use. Automatic transmission will select an appropriate gear ratio without any operator intervention . Sun and planet gear are mainly used

26/11/2009

Department of Mechanical and Automobile Engineering,

Institute of Technology and Management, Gurgaon

Design of Automobile Gearbox

Gearbox are incorporated to match performance of variable speed internal combustion engine. Lowest reduction ratio is needed at highest speed of operation, and vice versa, values of these reduction ratio lies b/w 3.5 to 4.5 for cars and 5 to 7 for commercial vehicles.Gearbox provides reduction ratio between 1:1 to 1:4 for cars to 1:1 to 1:7 for commercial vehicles.

26/11/2009

Department of Mechanical and Automobile Engineering,

Institute of Technology and Management, Gurgaon

Special features of Automobile Gear box

Universally accepted number of gear ratios is 4.These four are in geometric progression, However ,overdrive gear is provided to enhance performance at higher speeds Additional reduction ratio is provided to enhance performance during higher gradient operation.
Department of Mechanical and Automobile Engineering,
Institute of Technology and Management, Gurgaon

26/11/2009

Results Obtained

26/11/2009

Department of Mechanical and Automobile Engineering,

Institute of Technology and Management, Gurgaon

Gear Ratios
1st gear ratio 2nd gear ratio 4:1 2.52:1

3rd gear ratio

4th gear ratio 5th gear ratio 6th gear ratio 7th gear ratio

1.58:1
1:1 1.58:1 2.52:1 4:1

26/11/2009

Department of Mechanical and Automobile Engineering,

Institute of Technology and Management, Gurgaon

Layout

26/11/2009

Department of Mechanical and Automobile Engineering,

Institute of Technology and Management, Gurgaon

Results
Pitch line velocities for different gear pairs

Gear Pair GH AB CD EF
26/11/2009

Velocity(km/hr) 33.9 67.9 57 44.7

Department of Mechanical and Automobile Engineering,

Institute of Technology and Management, Gurgaon

Gantt Chart
Task 1. Problem Formulation 2.Literature and market survey 3.Design of gears and shafts 4. Cutting of gears Start Date 09/01/09 10/01/09 11/01/09 01/20/10 End Date Days Completed Days Remaining 09/30/09 10/31/09 11/30/09 02/28/10 21 31 25 0 0 0 5 38

5. Gear assembling and casing

6. Final Report 40 35 30 25

03/01/10
04/01/10

03/31/10
04/30/10

0
0

31
30

20
15 10 5 0 09/30/09 09/01/09 10/31/09 10/01/09 11/30/09 11/01/09 02/28/10 01/20/10 03/31/10 03/01/10 04/30/10 04/01/10

Days Completed Days Remaining

1. Problem 2.Literature and 3.Design of Formulation market survey gears and shafts

4. Cutting of 5. Gear 6. Final Report gears assembling and casing

26/11/2009

Department of Mechanical and Automobile Engineering,

Institute of Technology and Management, Gurgaon

Conclusion
Designing of gears and shafts has been done and near future we will be starting with fabrication of gearbox.

26/11/2009

Department of Mechanical and Automobile Engineering,

Institute of Technology and Management, Gurgaon

Acknowledgement
Project Advisor : Mr Pawan Taneja Help also taken from: Raman Rawal : Graduate Student Pankaj Sharma : Graduate Student

26/11/2009

Department of Mechanical and Automobile Engineering,

Institute of Technology and Management, Gurgaon

Bibliography
P.S.G Design Data book Handbook for engineers Material Science By Rk Rajput Mechanical System Design By S.P . Patil Theory of machine By Khurmi & Gupta Machine Design By Khurmi & Gupta

26/11/2009

Department of Mechanical and Automobile Engineering,

Institute of Technology and Management, Gurgaon