2 views

Uploaded by bernabas

nice one

nice one

© All Rights Reserved

- 2000 Nissan Frontier KA24DE AT
- articles_1_10.pdf
- Volvo i Shift
- Machine Design Final Report
- Manual Electronic Control System Caterpillar d5m d6m d6r Track Type Tractors Components Sensors Valves
- Ford Technology Newsletter 102010
- ZF6HP 053 VBL Interactive
- Eaton Clutch Selector
- 6-Speed Automatic Transaxle AWF21
- Columbia Maintenance Manual
- 797F Mining Truck
- volvo_242_244_245_owners_manual_1979
- Komatsu WA380 5
- Turner Compact Plus Transmission Manual
- mt_020_overhaul.pdf
- Embrague automatico
- rr_trdr-0400
- manual de mazda GF4EAL (1).pdf
- Cat Gkr Gks Gss Mh 15593811 en Gb
- QITA224

You are on page 1of 63

PHASE ONE

1. GEARBOX

1.1 INTRODUCTION

according to variety of road and load location. It also changes the engine speed into

torque when climbing hills and when the vehicle required. Main function of a

gearbox is as follow.

➢ Provide the torque needed to move the vehicle under the variety of road and

load condition. It does this by changing the gear ratio between the engine

crank shaft and vehicle drive wheels.

- Gears - shafts - bearings

Types of transmission system

1.3.1 Manual transmission

1.3.2 Automatic transmission

1.3.3 Semi-automatic transmission

1.3.1 Manual transmission

MECH-DESIGN

1|Page

Gear box design by Dawit Tesfaye KIOT 2009

applications. Manual transmissions often feature a driver-operated clutch

and a movable gear selector, although some do not. If you have a manual

transmission, you have to shift the gears yourself, usually with a stick

located on your console and the clutch pedal. Manual transmissions are

characterized by gear ratios that are selectable by engaging pairs of gears

inside the transmission.

There are three forms of manual transmission gearbox. Those forms are

If the dog clutches could be replaced by some kind of friction clutch perfect

Synchronization of the output shaft and the selected gearwheel could be

achieved rapidly and smoothly. A friction clutch strong enough to transmit

full torque would be far too big and heavy, but small clutch that had to do no

more than overcome the inertia of a freely rotating gearwheel and lay shaft

assembly could be quite small.

❖ The two synchromesh devices used in the gear box are constant load and baulk

ring. (5)

The earliest form of synchromesh gear box, commonly used in automotive gear box

is known as constant load type. The female cone of the clutch is formed in the hub,

MECH-DESIGN

2|Page

Gear box design by Dawit Tesfaye KIOT 2009

which has internal and external splines. A series of spring loaded balls are carried in

radial holes in the hub, and these push out wards in to a grooved machined in the

sleeve. Moments of selected fork carries the sleeve and hub on splines along the

main shaft towards the gear selected and allow the cone to contact. At these points

the gear while to suite the hub allows the hub and main (5)

Shaft.

The main advantage of the constant load synchronizer is that it is works on the

principle of friction. A friction clutch strong enough to transmit full torque would be

far too big and heavy, but small clutch that had to do no more than overcome the

inertia of a freely rotating gearwheel and lay shaft assembly could be quite small.

One of the oldest types, and operates by means of two Conical surface, whose

engagement is caused by the gear-change the friction surface brings the rotating parts

to a similar speed. Another member is also moved but delayed by a spring loading

arrangement. The teeth positively engaging the two rotating part. (2)

MECH-DESIGN

3|Page

Gear box design by Dawit Tesfaye KIOT 2009

1.4 Objective

1.4.1 Main objective:-

Drive power 75bhp@4000rpm and Drive torque 190Nm@1500- 2500rpm

MECH-DESIGN

4|Page

Gear box design by Dawit Tesfaye KIOT 2009

To know the general idea about manual gear box and its

component.

To calculate and design the required parameters of all the

components.

To know the application of manual transmission gearbox

To develop the idea and knowledge design.

ASSEMBLY

It is the determination of the engine power, engine torque and engine speed. The

power of the engine is driven by ‘p’ as:

𝑃 = 2𝜋𝑁𝑇/60

Case one: - indicating power:- is the power actually Developed in the cylinder.

Case two:-brake power (bp):- is the output power measured at the crankshaft.

2𝜋𝑁𝑇 2𝜋∗1800∗190

❖𝑃= = =35796watt=47.89hp

60 60

MECH-DESIGN

5|Page

Gear box design by Dawit Tesfaye KIOT 2009

❖ 𝑇 = 190𝑁𝑚

Therefore:-the brake power must less than indicating power b/c of mechanical

Losses

Friction losses

Pump losses

∴ip− fp= bp

Torque and speed have inversely proportional to each other

The gear ratio can be determined by considering the main shaft gear speed and the

speed of the engine shaft .on our design specification the value of gear ratio is

already given.so depend on our gear ratio we analyse (determine ) number of each

teeth .(1)

𝑔𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜 =

speed of the main shaft

✓ Top 0.5

✓ 4th 1

✓ 3rd 1.2

✓ 2nd 2.3

✓ 1st 3.3

✓ Reverse 3.5

MECH-DESIGN

6|Page

Gear box design by Dawit Tesfaye KIOT 2009

Then assuming the number of teeth for the lower pinions (NT=number of

teeth), NT for each gear is taking from standards. NTG1 is 20.

𝑇2

𝐺1 = = 3.3 𝑙𝑒𝑡 𝑢𝑠 𝑎𝑠𝑢𝑚𝑒 𝑇1 = 20

𝑇1

𝑇2

= 3.3 , 𝑇2 = 𝑇1 ∗ 3.3 = 20 ∗ 3.3 = 66

𝑇1

T4

𝐺2 = = 2.3 , 𝑇4 = 2.3 ∗ 𝑇3 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 𝑎𝑏𝑜𝑣𝑒 𝑒𝑞𝑢𝑒𝑠𝑡𝑖𝑜𝑛 𝑇1 + 𝑇2 = 𝑇3 + 𝑇4

T3

𝑇6

𝐺3 = = 1.2 , 𝑇6 = 1.2 ∗ 𝑇5 , 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 𝑎𝑏𝑜𝑣𝑒 𝑇3 + 𝑇4 = 𝑇5 + 𝑇6

𝑇5

𝑇8

𝐺4 = = 1 𝑠𝑖𝑛𝑐𝑒 𝑇8 = 𝑇7 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 𝑎𝑏𝑜𝑣𝑒 𝑇5 + 𝑇6 = 𝑇7 + 𝑇8

𝑇7

𝑇10

𝐺5 = = 0.5 , 𝑇10 = 0.5 ∗ 𝑇9 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 𝑎𝑏𝑜𝑣𝑒 𝑇7 + 𝑇8 = 𝑇9 + 𝑇10

𝑇9

MECH-DESIGN

7|Page

Gear box design by Dawit Tesfaye KIOT 2009

𝑇12 𝑇12 𝑇13 𝑇12

𝐺𝑟 = = 3.5 ∗ = We assume gear teeth of T11=18 b/c, the

𝑇11 𝑇13 𝑇11 𝑇11

𝑇12 63 𝑇13 32

= =1.968 &∗ = = 1.778 𝑠𝑜 1.968 ∗ 1.778 = 3.4999 =

𝑇13 32 𝑇11 18

4 DETERMINATION OF TORQUE

The input torque T1=T3=T5=T7=T9=T11 =190Nm, then the output torque are

calculated from the gear ratio.

𝑇2

𝐺1 = 3.3 =

𝑇1

T10=T9*0.5 =>190*0.5=95Nm

MECH-DESIGN

8|Page

Gear box design by Dawit Tesfaye KIOT 2009

1 20 190

2 66 627

3 26 190

4 60 437

5 39 190

6 47 228

7 43 190

8 43 190

9 57 190

10 29 95

11 18 190

12 63 665

5 SHAFT LAYOUT

Shaft is a rotating member, usually of circular cross section, used to transmit power

or motion. A vehicle gear box having

A) Input shaft

B) Output shaft

C) Counter shaft

Input shaft-transfer rotation from the clutch disc to the counter shaft gears. Any time

the clutch disc turns, the input shaft gear turns.

MECH-DESIGN

9|Page

Gear box design by Dawit Tesfaye KIOT 2009

Output shaft - holds the output gear and synchronizer, Connects to the drive shaft to

turn the wheels. Accept positively locked gear on output shaft the other gear is rotate

freely.

Counter shaft- holds the counter shaft gears into mesh with the input gear and other

gears. Located slightly below and to one slide of the input shaft. There are a number

of gears fixed along the counter shaft.(1)

6 TYPES OF SHAFTS

The following two types of shaft are important from the subject point of view

1. Transmission shafts: These shafts transmit power between the source and the

machine absorbing power. The counter shaft, lay shaft, overhead shaft and all factory

head shafts are transmission shafts since these shafts carry machine parts such as

pulley, gear etc. Therefore they are subjected to bending in addition to twisting

2. Machine shaft: The shafts from an inert parts of the machine itself. The crank shaft

is an example of machine shaft. That is shaft used to change reciprocating to rotation.

PHASE TWO

2 Gear design:-

2.1 Gears

Gears are toothed members which transmit power motion between two shafts by

meshing without any slip. Hence, gear drives are also called positive drives. In any

MECH-DESIGN

10 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

pair of gear the smaller one is called pinion and the larger one is called gear

immaterial of which is driving the other.

Spur gears:- is have teeth parallel to the axis of rotation and are used to

transmit motion from one shaft to another, parallel, shaft. Of all types, the spur

gear is the simplest and, for this reason, will be used to develop the primary

kinematic relationships of the tooth form.

Helical gears:- is have teeth inclined to the axis of rotation. Helical gears can

be used for the same applications as spur gears and, when so used, are not as

noisy, because of the more gradual engagement of the teeth during meshing.

The inclined tooth also develops thrust loads and bending couples, which are

not present with spur gearing. Hence helical gears give smooth drive with a

high efficiency of transmission but the disadvantage is a resultant thrust

along the axis of the gear.(6)

- greater load carrying capacity

- increase contact ratio

- smother than spur gear

MECH-DESIGN

11 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

N.B we select spur gear for reverse gear and helical gear for others gears for

our gear box design b/c of the following characteristics of both gears

rating precision

Spur gear • Parallel shafting. To all type of • Simplest tooth

• High speed and train and a elements aftering

load. wide range of max precision.

• Highest velocity ratio. • Recommended

efficiency. for all the gear

• Precision rating is meshes, except

excellent. where very high

speed and load or

special features of

other, such as

high angle drive,

cannot be

avoided.

MECH-DESIGN

12 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

gear • Very high speed applicable to spur, except for

and load. high speed and complicated of helix

• Efficiency load, also used angle.Recommonded for

slightly less than whenever spur all high speed and load

spur mesh. are used. meshes. Axial thrust

component must be

accommodated.

FOR calculate the module size and face width of the gear, we need to define the

1. Pitch circle. It is an imaginary circle which by pure rolling action, would give the

same motion as the actual gear.

MECH-DESIGN

13 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

2. Pitch circle diameter. It is the diameter of the pitch circle. The size of the gear is

usually specified by the pitch circle diameter. It is also called as pitch diameter.

4. Pitch surface. It is the surface of the rolling discs which the meshing gears have

replaced at the pitch circle.

5. Pressure angle or angle of obliquity. It is the angle between the common normal

to two gear teeth at the point of contact and the common tangent at the pitch point.

It is usually denoted by φ. The standard pressure angles are 14 /1 2° and 20°.

6. Addendum. It is the radial distance of a tooth from the pitch circle to the top of

the tooth.

7. Dedendum. It is the radial distance of a tooth from the pitch circle to the bottom

of the tooth.

8. Addendum circle. It is the circle drawn through the top of the teeth and is

concentric with the pitch circle.

9. Dedendum circle. It is the circle drawn through the bottom of the teeth. It is also

called root circle. Note: Root circle diameter = Pitch circle diameter × cos φ, where

φ is the pressure angle.

10. Circular pitch. It is the distance measured on the circumference of the pitch

circle from a point of one tooth to the corresponding point on the next tooth. It is

usually denoted by 𝑃𝑐

MECH-DESIGN

14 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

Where D = Diameter of the pitch circle, and T= Number of teeth on the wheel. A

little consideration will show that the two gears will mesh together correctly, if the

two wheels have the same circular pitch. (1)

Note: If 𝐷1 and 𝐷2 are the diameters of the two meshing gears having the teeth 𝑇1

and 𝑇2 respectively; then for them to mesh correctly,

𝜋 𝐷1 𝜋 𝐷2 𝐷1 𝑇1

𝑃𝑐 = = 𝑜𝑟 =

𝑇1 𝑇2 𝐷2 𝑇2

11. Diametric pitch. It is the ratio of number of teeth to the pitch circle diameter in

millimeters. It denoted by 𝑃𝑑. Mathematically,

𝑇 𝜋

Diametric pitch , 𝑃𝑑 = =

𝐷 𝑃𝑐

12. Module. It is the ratio of the pitch circle diameter in millimeters to the number

𝐷

of teeth. It is usually denoted by m. Mathematically, Module, 𝑚 =

𝑇

Note: The recommended series of modules in Indian Standard are 1, 1.25, 1.5, 2,

2.5, 3, 4, 5, 6, 8, 10, 12, 16, 20, 25, 32, 40 and 50. The modules 1.125, 1.375, 1.75,

2.25, 2.75, 3.5, 4.5, 5.5, 7, 9, 11, 14, 18, 22, 28, 36 and 45 are of second choice.

.13. Clearance. It is the radial distance from the top of the tooth to the bottom of the

tooth, in a meshing gear. A circle passing through the top of the meshing gear is

known as clearance circle. 14. Total depth. It is the radial distance between the

addendum and the addendum circle of a gear. It is equal to the sum of the addendum

and dedendum.

MECH-DESIGN

15 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

The standard module in helical gear is the range between 2.5 to 3.5 but we

can take or use 3mm. by using these module and the number of teeth in each gear

use confine the diametric pitch

2.4 Determine the pitch diameter (𝑝𝑐 ) for each teeth

For first gear (𝑮𝟏 )

𝑑𝑎

𝑇1= 20 𝑑1 = 𝑀𝑇=3 ×20=60→ 𝑟1 = =30mm

2

C1=𝑟1 + 𝑟2 = 30+99=129mm

MECH-DESIGN

16 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

C2=r3+r4= 39+90=129mm

C4=129mm

C5=81mm

MECH-DESIGN

17 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

T->no of teeth

𝜶=helix angel 200-450 for our design we select 350

∅ =pressure angle 200

MECH-DESIGN

18 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

T1

Gear 1 Tangential force (Ft) = =190Nm/30mm =6333.3N

𝑟1

Ft tan ∅ 6333.3∗0.364

Radial force 𝐹𝑟 = = =2811.4N

cos 𝛼 0.82

T2

Gear 2 Ft = =627Nm/99mm =6333.33N

𝑟1

6333.3∗0.364

Fr = =2811.4N

0.82

4871.8∗0.364

Fr = =2162.6N

0.82

4855.6∗0.364

Fr = =2155.4N

0.82

3247.9∗0.364

Fr = =1441.7N

0.82

3234∗0.364

Fr = =1435.6N

0.82

MECH-DESIGN

19 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

gear 7 =gear 8”

2945.74∗0.364

Fr = =1307.6N

0.82

2222.2∗0.364

Fr = =986.44N

0.82

2183.9∗0.364

Fr = =969.44N

0.82

∅ =pressure angel .we select 200

T11

Gear 11 Ft = =190Nm/27mm =7037N

𝑟11

MECH-DESIGN

20 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

T12

Gear 12 Ft = =665Nm/94.5mm =7037N

𝑟12

.

𝑭𝒕

𝝈= = Ft=m∗ 𝛿𝑎𝑙𝑙 *y *f

𝒇𝒚𝑫

NB “when we use above formula for our design we must assume factor

of safety .for factor safety assumption must we select material and we

𝛿𝑢𝑙𝑡

use ultimate strength of our material 𝛿𝑎𝑙𝑙 = so we will get

𝑓𝑠

stress is not our design working stress .b/c of that I don’t use the above

formula. Instead of that we used the next derived formula. “ (1)

MECH-DESIGN

21 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

Overlap =b*tanα=1.15*Pc

1.15 ∗ 𝑝c 1.15 ∗ 𝜋𝑚 𝛱𝑑

𝑏= = =

tan 𝛼 𝑡𝑎𝑛 𝛼 𝑃𝑐 𝑇

M =module

NB: The face width of helical gear is equal.so by using the below formula we can

calculate our face width and we get it equal value of face width for all helical and

spur gears.

1.15 ∗ 𝑝c 1.15 ∗ 𝜋𝐷

b= =

tan 𝛼 𝑡𝑎𝑛 𝛼 𝑇

q= 𝜋 ∗ 𝑚 = 3.14 ∗ 3 = 9.42

Example for

MECH-DESIGN

22 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

Gear one

1.15 ∗ 𝜋 ∗ 60

b1 = = 29.76𝑚𝑚

𝑡𝑎𝑛 20 ∗ 20

Gear two

1.15 ∗ 𝜋 ∗ 198

b2 = = 29.76𝑚𝑚

𝑡𝑎𝑛 20 ∗ 66

b1=b2=b3=b4=b5=b6=b7=b8=b9=b10=b11=b12=b13=29.76mm

So when we check our face width b=29.76

Therefore 3*9.42<b<5*9.42

28.26mm< 29.76mm <47.1mm so our face width value is safe

❖ By using tangential load and Lewis factor we can calculate the maximum

bending stress and we select the gear material for our gear design

𝑭𝒕

𝝈= the maximum tangential load is appeared on gear 1 and 2

𝒃𝒎𝒚

so we select Ft =6333.3 N and we have the maximum tooth number is 66

in gear 2 so we select the Lewis factor from below table

MECH-DESIGN

23 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

𝑭𝒕 6333.3

Y =0.422 so 𝝈= = 29.76∗3∗ = 168 N/m2

𝒃𝒎𝒚 0.422

So depend on this stress we select the material having greater tensile strength.

The selection of a proper material, for engineering purposes, is one of the most

difficult problem for the designer. The best material is one

Which serve the desired objective at the minimum cost. The following factors should

be considered while selecting the materials:

High endurance strength to with stand dynamic load

Low coefficient of friction

MECH-DESIGN

24 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

Good manufacturability

Depend on the above considered we select “”GRAY CAST IRON” for our project

b/c of having the following property

Due to the above characteristics we select grade of FG 600 that means the tensile

strength is 630 pa. So our factor of safety Fs =630/168 =3.75 (6)

The speed of N1 = N3 = N5 = N7 = N9 = N11 = 1800 rpm is accepted from

given parameter of speed between 1(500-2500 rpm, S0 by using below formula

we can calculate the value of N2, N4, N6, N8, N10, & N12.

𝑵𝟏

V.R=velocity ratio =gear ratio V.R=

𝑵𝟐

𝑵𝟏

1st gear ratio 3.3= =1800/N2

𝑵𝟐

N2=1800/3.3 =545.45rpm

𝑵𝟑

2nd gear ratio 2.3=

𝑵𝟒

MECH-DESIGN

25 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

N4=1800/2.3=782.6rpm

𝑵𝟓

3rd gear ratio 1.2=

𝑵𝟔

N6=1800/1.2=1500rpm

𝑵𝟕

4th gear ratio 1=

𝑵𝟖

N8 =N7

𝑵𝟗

5th gear ratio 0.5=

𝑵𝟏𝟎

N10=1800/0.5=3600rpm

𝑵𝟏𝟏

Reverse gear ratio 3.5= N12=1800/3.5=514.3rpm

𝑵𝟏𝟐

GEAR

𝜋𝐷𝑝𝑁

Vm = in meter per second where DP =pitch diameter

60∗1000

πD1N1 3.14∗60∗1800

FOR gear 1 V1= = =5.65m/s

60∗1000 60∗1000

πD2N2 3.14∗198∗545.45

For gear 2 V2 = = =5.65m/s

60∗1000 60∗1000

MECH-DESIGN

26 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

πD3N3 3.14∗78∗1800

For gear 3 V3 = = =7.35m/s

60∗1000 60∗1000

πD4N4 3.14∗180∗782.6

For gear 4 V4= = =7.372m/s

60∗1000 60∗1000

πD5N5 3.14∗117∗1800

For gear 5 V5= = =11.02m/s

60∗1000 60∗1000

πD6N6 3.14∗141∗1500

For gear 6 V6= = =11.07m/s

60∗1000 60∗1000

πD7N7 3.14∗129∗1800

For gear 7 V7= = =12.15m/s = V8=V7

60∗1000 60∗1000

πD9N9 3.14∗171∗1800

For gear 9 V9= = =16.11m/s

60∗1000 60∗1000

πD10N10 3.14∗87∗3600

For gear 10 V10= = =16.4m/s

60∗1000 60∗1000

πD11N11 3.14∗54∗1800

For gear 11 V11= = =5.08m/s

60∗1000 60∗1000

πD12N12 3.14∗189∗514.3

For gear 12 V12= = =5.08m/s

60∗1000 60∗1000

load mm m/s

MECH-DESIGN

27 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

In the previous article, the velocity factor was used to make approximate allowance

for the effect of dynamic loading. The dynamic loads are due to the following

reasons:

A closer approximation to the actual conditions may be made by the use of equations

based on extensive series of tests, as follows:

MECH-DESIGN

28 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

WD = WT + WI

The increment load (WI) depends upon the pitch line velocity, the face width,

material of the gears, the accuracy of cut and the tangential load. For average

conditions, the dynamic load is determined by using the following Buckingham

equation, i.e.

A deformation factor (C) depends upon the error in action between teeth, the class

of cut of the gears, the tooth form and the material of the gears. The following table

shows the values of deformation factor (C) for checking the dynamic load on gears.

MECH-DESIGN

29 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

We select values of deformation factor =57 b/c of we select 14.5 involute tooth form

and cast iron for our design. The increase of the pressure angle from

14 /2° to 20° results in a stronger tooth, because the tooth acting as a beam is

Wider at the base/c of that we select our pressure angle 20.

𝟐𝟏𝒗(𝒃 ∗ 𝒄 𝒄𝒐𝒔 𝟐∝ + 𝑭𝒕) 𝒄𝒐𝒔 𝜶

𝑭 𝑫 = 𝑭𝑻 +

𝟐𝟏𝒗 + √𝒃 ∗ 𝒄 𝒄𝒐𝒔 𝟐∝ + 𝑭𝒕

Pressure angle & Helix angle, φ = 15° to 25° & α = 20° to 45° respectively for

helical gear.so we select value of helix angle for our project α=35 0 (6)

Face width and helix angle are constant for all helical gear ,b=29.76mm

21v1(b∗c cos 2∝ +Ft) cos α

FD 1= FT 1 +

21v1+√b∗c cos 2∝ +Ft

=6333.3 +

21∗5.65+√29.76∗55 cos 235 +6333.3

=9655.275N

MECH-DESIGN

30 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

FD 2 = FT 2 +

21v2+√b∗c cos 2∝ +Ft

= 6333.3 +

21∗5.65+√29.76∗55 cos 235 +6333.3

=9655.275N

21v3(b∗c cos 2∝ +Ft) cos α

FD 3= FT 3 +

21v3+√b∗c cos 2∝ +Ft

= 4871.8 +

21∗7.35+√29.76∗55 cos 235 +4871.8

=7883.219N

21v4(b∗c cos 2∝ +Ft) cos α

FD 4 = FT 4 +

21v4+√b∗c cos 2∝ +Ft

=4855.6+

21∗7.37+√29.76∗55 cos 235 +4855.6

=7862.12N

21v5(b∗c cos 2∝ +Ft) cos α

FD 5 = FT 5 +

21v5+√b∗c cos 2∝ +Ft

= 3247.9 +

21∗11.02+√29.76∗55 cos 235 +3247.9

=6010.392N

FD 6= FT 6 +

21v6+√b∗c cos 2∝ +Ft

= 3234 +

21∗11.07+√29.76∗55 cos 235 +3234

MECH-DESIGN

31 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

=5690.779N

21v7(b∗c cos 2∝ +Ft) cos α

FD 7 = FT 7 +

21v7+√b∗c cos 2∝ +Ft

= 2945.74 +

21∗12.15+√29.76∗55 cos 235 +2945.74

=5276.476N

21v8(b∗c cos 2∝ +Ft) cos α

FD 8= FT 8 +

21v8+√b∗c cos 2∝ +Ft

=2945.74 +

21∗12.15+√29.76∗55 cos 235 +2945.74

=5276.476N

FD 9= FT 9 +

21v9+√b∗c cos 2∝ +Ft

= 2222.2 +

21∗16.11+√29.76∗55 cos 235 +2222.2

=4193.722N

FD 10= FT 10 +

21v10+√b∗c cos 2∝ +Ft

= 2183.9 +

21∗16.4+√29.76∗55 cos 235 +2183.9

=4134.718N

MECH-DESIGN

32 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

21v(bC+WT)

FD = WT + WI =𝑊𝑇 + where

21v+√bc+WT

WT= Steady transmitted load in newton’s,

v = Pitch line velocity in m/s,

b= Face width of gears in mm, and

C= A deformation or dynamic factor in N/mm

c = 57 N/mm deformation factor from Table 28.5. Values of deformation

factor (C), for full depth cast iron Gear is(3).

b=29.76mm

𝟐𝟏𝐯(𝐛𝐂+𝐖𝐓𝟏𝟏) 21∗5.08∗(29.76∗55+7037)

FD11=𝐅𝐓𝟏𝟏 + 𝟐𝟏𝐯+√𝐛𝐜+𝐖𝐓𝟏𝟏 = 7037 + =124.3N

21∗5.08+√(29.76∗55+7037)

𝟐𝟏𝐯(𝐛𝐂+𝐖𝐓𝟏𝟐) 21∗5.08∗(29.76∗55+7037)

FD12=𝐅𝐓𝟏𝟐 + 𝟐𝟏𝐯+√𝐛𝐜+𝐖𝐓𝟏𝟐 = 7037 + =124.3N

21∗5.08+√(29.76∗55+7037)

The maximum load that gear teeth can carry, without premature wear, depends upon

the radii of curvature of the tooth profiles and on the elasticity and surface fatigue

limits of the materials. The maximum or the limiting load for satisfactory wear of

gear teeth, is obtained by using the following Buckingham equation, i.e.

Ww = DP . b. Q. K Where

MECH-DESIGN

33 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

✓ Q= Ratio factor

2∗𝑉.𝑅 2𝑇𝐺

= = for external gears

𝑉.𝑅+1 𝑇𝐺+ 𝑇𝑃

N/mm

2 2

Ww = DP . b. Q. K K=0. 714 *(δs2*sinα) =0.714(630, 0002* Sin35)*

E 90000

=3.15N/mm2

Q1 = = =1.53 Q2 = = =0.565

T2 +T1 66+20 T2 +T3 66+26

Q3 = = =1.396 Q4 = = =0.788

T3 +T4 26+60 T4 +T5 60+39

Q5 = = = 1.09 Q6 = = = 0.955

T5 +T6 39+47 T6 +T7 47+43

Q7 = = =1 Q8 = = =1

T7 +T8 43+43 T8 +T9 43+43

Q9 = = = 0.67 Q10 = = = 0.76

T9 +T10 57+29 T10 +T11 29+18

Q11 = = = 1.55 Q12 = = = 0.67

T11+T12 18+63 T12+T13 63+32

MECH-DESIGN

34 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

DP1 .b.Q1.K

Ww 1 = =( 60*29.76*1.53*3.15)/0.67=12844N

cos2 35

DP2 .b.Q2.K

Ww 2 = = (198*29.76*0.565*3.15)/0.67=15652N

cos2 35

DP3 .b.Q3.K

Ww 3 = = (78*29.76*1.396*3.15)/0.67=15235N

cos2 35

DP4 .b.Q4.K

Ww 4 = = (180*29.76*0.788*3.15)/0.67=1984N

cos2 35

DP5 .b.Q5.K

Ww 5 = = (117*29.76*1.09*3.15)/0.67=19546N

cos2 35

DP6 .b.Q5.K

Ww 6 = = (141*29.76*0.955*3.15)/0.67=20637N

cos2 35

DP7 .b.Q7.K

Ww 7 = =Ww 8 =(129*29.76*1*3.15)/0.67 =18049N

cos2 35

DP10 .b.Q10.K

Ww 10= =(87*29.76*0.76*3.15)/0.67=9252N

cos2 35

Gear 1 9655.3N < 12844N

MECH-DESIGN

35 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

Gear 3 7883N < 15235N

Gear 4 78.62N < 1984N

Gear 5 6010N < 19546N

Gear 6 5691N < 20637N

Gear 7 5277N < 18049N

Gear 8 5277N < 18049N

Gear 9 4194N < 6193N

Gear 10 4135N < 9252N

Gear 11 124.3N < 7848N

Gear 12 124.3N < 11871N

Therefore:- b/c of dynamic load of our gear less than wear load,

MECH-DESIGN

36 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

Phase three

3 SHAFT DESIGN

Shaft is a rotating member, in general has a circular cross section and is used to

transmit power. The power is delivered to the shaft by some tangential force and the

resultant torque set up with in the shaft permits the power to be transferred various

machine linked up to the shaft .In order to transfer the power from one shaft to

another, the various member such as pulleys, gears etc. are mounted on it.

The following stresses are induced in the shaft; Shear stresses due to transmission of

torque i.e. due to torsion load.

Bending stresses (tensile or compressive) due to the force acting upon

machine elements like gear and pulley etc. . . . . As well as due to the weight

of the shaft itself.

Stresses due to combined torsion and bending load. (1)

considered.

Shafts subjected to twisting moment on torque only

Shafts subjected to bending moment only

Shafts subjected to combined twisting and bending moment

Shafts subjected to axial load in addition to combined tensional and bending

loads. (2)

Maximum Shear force

MECH-DESIGN

37 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

1. To minimize both deflections and stresses, the shaft length should be kept as

short as possible and overhangs minimized.

2. A cantilever beam will have a larger deflection than a simply supported

(straddle mounted) one for the same length, load, and cross section, so straddle

mounting should be used unless a cantilever shaft is dictated by design

constraints.

3. A hollow shaft has a better stiffness/mass ratio (specific stiffness) and higher

natural frequencies than a comparably stiff or strong solid shaft, but will be

more expensive and larger in diameter.

4. Try to locate stress-raisers away from regions of large bending moment if

possible and minimize their effects with generous radii and relief.

5. General low carbon steel is just as good as higher strength steels (since

deflection is typical the design limiting issue).

6. Deflections at gears carried on the shaft should not exceed about 0.005 inches

and the relative slope between the gears axes should be less than about 0.03

degrees.(4)

3.3 MATERIAL SELECTION FOR SHAFTS

The material used for shafts should have the following properties;

❖ It should have high strength

❖ It should have good machinability

❖ It should have low notch sensitivity factor

❖ It should have good heat treatment properties

❖ It should have high wear resistance properties (4)

MECH-DESIGN

38 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

Fr

Fr Fr Fr Fr Fr

Ft

Fa Ft Ft Ft

Ft

Fa Ft

Fa Fa

Fa

2 4 6 8 10 12

20mm 1 1 20

0 0 150mm

150mm

30mm

30 30mm

30

30

30mm

MECH-DESIGN

39 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

Fr 2 Fr 4 Fr 6 Fr 8 Fr 10 Fr 12

6.39kN

6.54kN

6.39

3.83

1.27

SHEAR

FORCE

-0.004

DIAGRAM

-1.47 in KN

MAX -3.733

SHEAR

FORCE -6.54

BENDING

MOMENT

DIAGRAM

IN

0.23

MAX 0.22 KN

BENDING per m

MOMENTEM

0.9 0.9

0.96 0.96

For our design we not gain full given so we must flow our assumption

shear force

MECH-DESIGN

40 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

not know our working stress ,so we must assume diameter for our design

𝑇𝑒 = √𝑀2 + 𝑇 2 (6)

Tmax=627Nm

𝑇𝑒 = √𝑀2 + 𝑇 2 =√9602 + 6272 =1147Nm

𝜋

Te= 𝜏warking d3

16

1147=0.19625*𝜏*0.063

𝜏w =27Mpa

We Assume our factor of safety n=8 is large number b/c of not know our exact

working stress

MECH-DESIGN

41 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

𝑦𝑖𝑙𝑑 𝑠𝑡𝑟𝑒𝑠𝑠

=>n= yield strength=8*27=216Mpa

𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠

We know working stress then we can select material. The material of the shafts is

plan carbon steel 50C.4 with ultimate tensile strength =440-760= and Yield strength

320Mpa from van mosses stress theory of failure

320

n= = 10 so our design is safe

27

We have input speed 4000rpm and power 75hp=55950watt Torque =133.64Nm

𝑇𝑎 𝑁𝑏 4000

Therefor gear ratio= = = =2.2222

𝑇𝑏 𝑁𝑎 1800

𝑇𝑎

Assume Tb =20 tooth =2.222

20

Db=mTb=3*20=60mm ra=67.5mm rb=30mm

𝑇𝑎 190𝑁𝑚 𝑇𝑏 133.64𝑁𝑚

Fta= = =2815NFtb== = =4454N

𝑟𝑎 0.0675𝑚 𝑟𝑏 0.03𝑚

Fra= = = 1250NFrb= = =1977N

cos 𝛼 0.82 cos 𝛼 0.82

MECH-DESIGN

42 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

Fr

Ft

Fa

a

input shaft

30mm

30

30 30 30

30

30

30

7 9

11

b 1 3 5 150

20 150 150

150 20

Fa

Ft Fa

Fr

Ft Fa

Fr Fa

Ft

Ft

Fr Fa Fr

Ft

Fr

Fa

Ft

Fr

Ft

Fr

counter shaft

MECH-DESIGN

43 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

Fr b

0.99

Shear force

0.99

Moment dia

0.06

MECH-DESIGN

44 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

Fr a Fr 1 Fr 3 Fr 5 Fr 7 Fr 9 Fr 11

6.57

4.01

3.03

1.72

0.28 SHEAR

FORCE

DIAGRAM

in KN

1.87

4.7

5.96

BENDING

MOMENT

MAX

DIAGRAM

BENDING

0.21 IN

MOMENTEM 0.23

KN

1.05 1.07 0.95

per m

1.4 1.4

MECH-DESIGN

45 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

Both of them counter and input shafts are not have other different concepts

Tmax=190 Nm

𝑇𝑒 = √𝑀2 + 𝑇 2 =√14002 + 1902 =1413Nm

𝜋

Te= 𝜏warking d3

16

1413=0.19625*𝜏*0.063

We Assume our factor of safety n=8 is large number b/c of not know our exact

working stress

𝑦𝑖𝑙𝑑 𝑠𝑡𝑟𝑒𝑠𝑠

=>n= yield strength=8*33.3=266.4Mpa

𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠

We know working stress then we can select material. The material of the shafts is

plan carbon steel 50C.4 with ultimate tensile strength =440-760= and Yield strength

320Mpa from van mosses stress theory of failure

MECH-DESIGN

46 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

320>266

320

n= = 9.6 so our design is safe

33.3

Assume for input shaft the same as counter and main shaft

D=60mm

𝜋

Te= 𝜏warking d3

16

146.3=0.19625*𝜏*0.063

𝜏w =3.45Mpa

We us the same material as privies design and our work is more safe

PHASE FOUR

4.1 BEARING DESIGN

MECH-DESIGN

47 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

It permits of a relative motion between contact surfaces of the members, while

carrying the head a little considering shown that due to the relative between the

contact surfaces, a certain amount of power is wasted in overcoming frictional

resistance and if the rubbing surfaces are in direct contact. There will be rapid wear

in order to reduce frictional resistance and wear and in some cases. To carry away

the heat generated, layer of fluid (known as lubricant) may be provide .Material

selected for bearing design is bronze steel because it has high wear resistance and

strength. For this design the selected bearing is rolling contact bearing. (1)

In rolling contact bearing in the contact between the bearing surfaces is rolling

instead of sliding as in sliding constant bearings.

MECH-DESIGN

48 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

➢ Low starting and running friction except at very high speeds

➢ Ability to with stands momentary shock loads.

➢ Accuracy of alignment.

➢ Low cost of maintenance.

➢ Small over all dimensions.

➢ Reliability of services.

➢ Easy to mount and erect

➢ Cleanliness

4.1.3 TYPES OF ROLLING CONTACT BEARING

1 ball bearing

2 roller bearing

The selected single row groove ball bearing for this design. Double row

bearing made with radial or contact between the balls of races. Double row bearing

is applicable than two single row bearing. So, by selecting a single row deep groove

ball bearing for a radius head is (2811.4N) maximum valve. And axial head (4434.62

N) operating as speed 1800rpm.

Assuming for an average life 10 years at 9 hours per day and uniform and

steady state.

LH=10*320*9=28800hrs

Assuming 320 day per year and life of bearing in the revolution.

MECH-DESIGN

49 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

LB=60*NLH=60*1800*28800

V=rotational factor

FR=radial load

FA=axial load

𝐹𝐴

Therefore let us take = 0.5 now from standard table 27.4 (text of machine design

𝐶𝑜

𝐹𝐴 𝐹𝐴

page 1008). We find that the value of x and y corresponds to = 0.5 and =

𝐶𝑜 𝐹𝑅

4434.62𝑁

= 1.5774 which is greater than e=0.44 (6)

2811.4𝑁

Since the rotational factor (v) for most of the bearings is 1. Therefore basic dynamic

equivalent radial load.

F=x*v*FR+Y*FA

F= 0.56*1*2811.4+1*4434.62

F= 6009.004N

To find uniform and steady load, if the services factor (Ks) for ball bearing is 1.

Therefore bearing should be selected for F = 6009.004N

𝐿𝐵 1⁄

C=F[ ] 𝑘 [k=3 for all bearings]

106

MECH-DESIGN

50 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

311∗107 1

C= 6009.004[ ]3 = 87.711KN

106

Let us select the bearing number 314 from standard table 27.1 and table 27.6(text

book of machine design page 1000 and 1013) which have the following capacity.

Co=63KN=63000N and C=81.5KN=81.5000N

Bore = 70mm

Width = 24 mm

𝐹𝐴 4434.62

= =0.0703

𝐶𝑜 63000

X=0.56 y=1.6

MECH-DESIGN

51 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

F=x*v*FR+Y*FA

= 0.56*1*2811.4+1.6*4434.62

F=8669.78N=8.67KN

1⁄3

311∗107

C=F

𝐿𝐵

[ 6 ]1⁄𝑘 = 8669.78[ ] = 126.55𝐾𝑁

106

10

A key is piece of mild steel inserted between the shaft and hub or boss of pulley to

connect this together in order to prevent relative motion between them, it always

inserted parallel to axis of shaft.

Keys are used as temporary fastenings and are subjected to considerable crashing

and shearing stresses .a key way is a slot or recess in shaft to the supporting element.

Key can be used on shaft to rotating element, such as gears, pulleys or other

elements, such as wheels, keys are used to enable transmission of torque from the

shaft to the supporting element.

Material selected for key is mild steel because it has high heat transfer and strength

and also,keys can be classified as

➢ parallel key

➢ Tapered key

➢ wood ruff key

➢ Gibb-head key

➢ Sun key

MECH-DESIGN

52 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

The selected key is sun key because it is suitable for heavy duty application since

there is no possibility the key to slip along the shaft. It is positive drive. This is main

advantages of sun key above saddle key. (3)

The material of the key is the same as input shaft 𝑆𝑦𝑡 =440_760N/𝑚𝑚2 and factor of

safety=3

𝑆𝑦𝑡

𝑆𝑦 = = 440/8 = 55 𝑁/𝑚𝑚2

𝑓𝑠

𝑆𝑆𝑦 =0.5*Syt=0.5*440=220N/𝑚𝑚2

𝑆𝑠𝑦 220

𝜏= = = 27.5𝑁/𝑚𝑚2

𝑓𝑠 8

𝑑 60

T=L*W*𝜏 ∗ = 𝑙 ∗ 18 ∗ 27.5 ∗ =14850𝑙Nmm

2 2

𝜋 𝜋

T= *𝜏 ∗ 𝑑 3 = ∗ 27.5 ∗ 603

16 16

T= 1.16*106 Nmm

1.16∗106

L= = 78.54mm

14850

MECH-DESIGN

53 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

𝑡 𝑑 11 60

T=L* ∗ 𝛿𝑐 ∗ =T=L* ∗ 55 ∗

2 2 2 2

T=9075L N/mm

1.16∗106

L= =127.82 mm

9075

𝑑 60

T=L*W*𝜏 ∗ =L*18*27.5*

2 2

T =14850 L Nm

𝜋

T= *27.5*603 =1.16*106 Nm

16

1.16∗106

L= = 78.54𝑚𝑚

14850

𝑡 𝑑 11 60

T=L* *𝛿𝑐 ∗ =L* ∗ 55 ∗

2 2 2 2

T=9075L Nm

1.16∗106

L= =127.82mm

9075

MECH-DESIGN

54 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

Gear box housing or casing are containers in which the internals, namely, the gears,

the shafts, bearings, oil seals, bearing covers and other components mounted as a

material for gear box casings, good quality cast iron is damping properties and free

from noise .Suitable gaskets are provided between them to secure tightness against

entry of dust and leaking of oil

➢ Abase for mounting gears.

➢ Ensure a relative alignment of their axis.

➢ A support for bearing and bearing seals and as an oil both for gears.

✓ Material selected for housing is grey steel casting, because it has high noise

resistance and high strength to support all force.

The housing dimensions of three shafts two stages reduce units can be determined

from the following empirical relation.

Known values

➢ The largest outside diameter of main shaft gear (Do2) = 204

➢ Center distances between counter shaft and output shaft (C1)

𝐷1 𝐷2 30 198

C1 = + = + =114mm

2 2 2 2

MECH-DESIGN

55 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

𝐷𝑏 𝐷𝑎 60 135

C2= + = + = 97.5𝑚𝑚

2 2 2 2

𝐷𝑜2 𝐷𝑂9

L= +C1+ +𝐶

2 2

204 177

𝐿= + 114 + + 50𝑚𝑚 = 354.5𝑚𝑚

2 2

We select steel castings which are case hardened so having these dimensions the

wall thickness(S) of the gear box can be found according to the following table.

s=0.007L+ 4mm

=0.007(354.5) +4

=6.4815 mm

The largest length of the gear box is the length of the lay shaft=870 mm

MECH-DESIGN

56 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

4.4 LUBRICATION

systemFluid which is introduced in between moving parts in order to reduce the

friction, generated heat & wear and tear of machine parts are called Lubricants. This

process of introducing lubricant is called Lubrication.

When one surface moves over another, there is always some resistance to

movement, and the force, which opposes movement, is called friction. If the friction

is low and steady, there will be smooth, easy movement. At the other extreme, the

friction may be so great or uneven, that movement becomes challenging or

the surfaces can overheat or be seriously damaged.

of one surface over another, and the material used to facilitate this process is called

lubricant. Lubricants are usually liquids or semi liquids, but may be solids, gases, or

any combination of solids, liquids and gases. In addition to reducing or

controlling friction, lubricants are usually expected to reduce wear and often

to prevent overheating and corrosion.

Lubricants are usually divided into four basic classes, these are:

Oils: - a general term used to cover all liquid lubricants, whether they are mineral

oils, natural oils, synthetics, and process fluids.

MECH-DESIGN

57 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

Greases: - there are oils, which contain a thickening agent to make them semisolid,

but it is sometimes convenient to include anti-seize pastes and the semi-fluid greases

under the same leading.

Dry lubricants: - there include any lubricants, which are used in solid form and

may be bulk solids, point like coatings or loose powders.

Gases: - the gases usually used in gas bearings is air, but any gas can be used which

will not attack the bearings, or itself decomposed.

Reduces the frictional resistance.

Reduces wear & tear, surface deformation

Acts as a coolant

Provides protection against corrosion

Acts as a seal in some cases

Improves the efficiency of the machine

The two main factors needed for selecting the type of lubricants are speed and the

load. At high speed, we need less viscous lubricant, where as to increase the load

and decrease the speed, we need higher viscous lubricant. Viscosity, film strength,

lubricity, adhesion, gear speed and temperature are applicable characteristics to all

gear lubricants.

Manual Power transmission system From the oil type lubricants, we selected mineral

oil because of Wide range of viscosity are available, Good boundary lubrication,

Long life and Cheap (low cost)

MECH-DESIGN

58 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

There are two methods recommended for lubricating gears

➢ The pressure or jet method

The splash method in which the gear deeps in oil dump in the bottom of the gearbox

is satisfactory for gears operating at peripheral speeds up to 2000 rpm. At higher

speeds, churning of the oil is likely to cause overheating. For speeds above 2000-

rpm jet oil should be directed on the leaving side of mesh point to cover the

full strength of the teeth on both members. If the drive is reversible, jets

should be directed at both the entering and leaving mesh.so we have selected splash

method for our gear box (4)

Enough oiliness to reduce the friction between the rubbing tooth surfaces

Enough viscosity to develop a suitable film between the tooth surfaces

It should remove the heat developed by the gears fast enough

It should flash away the wear products and corrosion formed on the tooth

surfaces

No dirt and metal particles, sludge or acids should mix with the lubricant

extreme pressure gear lubricant, available in two viscosity grades (ISO 320 and 680),

used in General Electric wheel motors used in mining haul trucks. Syncon-Premium

EP Gear Oil is formulated with synthetic polyalphaolefin (PAO) base oils, a

no chlorinated extreme pressure additive and select inhibitors. It has outstanding

oxidation resistance and thermal stability at high temperatures to help minimize

MECH-DESIGN

59 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

deposit formation and provide long service life. It has high load-carrying capacity to

protect against scuffing and wear, and protects against rust, corrosion and foaming

4.4.5 APPLICATIONS:

GE wheel motors found in mining haul trucks

Enclosed industrial gearboxes operating at very high or very low

temperatures, or operating continuously at higher than normal operating

temperatures.

Heavily loaded plain and rolling-element bearings operating under extreme

temperatures.

Applications where the manufacturer recommends a synthetic EP gear

oil 1 Syncon Premium EP Gear Oil is not recommended for use in worm gear

drives with bronze-on-steel gears, or in automotive differentials with hypoid

gears.

4.4.6 FEATURES/BENEFITS:

Outstanding oxidation resistance and thermal stability at high temperatures

Outstanding low-temperature properties

High load-carrying capacity

Suitable for year-round use

Extended service intervals compared with conventional mineral oil based

MECH-DESIGN

60 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

Conclusion

In this project we have discussed about manual transmission system and is parts we

have designed the slid mesh gear box .we have designed and calculated the

fundamentals parts of the gears, shaft, bearing and lubrication needed for the them

is analyzed and suggested accordingly at the end the design is checked and proved

safe. Finally we would like to suggest that extending this project in detail and further

analysis can be made in software to know the most venerable parts of the design

MECH-DESIGN

61 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

REFERENCE

2,hh://en.m.wikipedia.org/wiki/Manual_transmission

3,www.howacarworks.com/basics/how-manual-gearboxes-work

5, Wikipedia (www.wikipedia.org)

MECH-DESIGN

62 | P a g e

Gear box design by Dawit Tesfaye KIOT 2009

MECH-DESIGN

63 | P a g e

- 2000 Nissan Frontier KA24DE ATUploaded byDavid Cervantes
- articles_1_10.pdfUploaded byLuisYFer1
- Volvo i ShiftUploaded byHugh Sago
- Machine Design Final ReportUploaded byAvk Sanjeevan
- Manual Electronic Control System Caterpillar d5m d6m d6r Track Type Tractors Components Sensors ValvesUploaded byRoussel Florez Zuloaga
- Ford Technology Newsletter 102010Uploaded byfordfiesta_my
- ZF6HP 053 VBL InteractiveUploaded byMauricio Exequiel Chavez
- Eaton Clutch SelectorUploaded byrandy1111
- 6-Speed Automatic Transaxle AWF21Uploaded bylovre1
- Columbia Maintenance ManualUploaded byLuis Enrique Lopez Rojas
- 797F Mining TruckUploaded byx_leyder182
- volvo_242_244_245_owners_manual_1979Uploaded bysander_kart
- Komatsu WA380 5Uploaded byJose Pichinte
- Turner Compact Plus Transmission ManualUploaded bybeto06
- mt_020_overhaul.pdfUploaded byMarius
- Embrague automaticoUploaded byRandy Staemly Marcella Pacifico
- rr_trdr-0400Uploaded byGeorge Buitrago
- manual de mazda GF4EAL (1).pdfUploaded byNATHALY
- Cat Gkr Gks Gss Mh 15593811 en GbUploaded bydavid
- QITA224Uploaded byChandan Eshwara
- ANL 064 TCA With Shafts 1Uploaded byRakeshPatilR
- VW Passat B6 2005 - Electro-mechanical steering gearUploaded byNP
- semester mutli-modalUploaded byapi-273182440
- M6 Coupe Convertible CatalogueUploaded byIvan Miralles Barra
- Frlo Lightning Series Manual ServiceUploaded byAdal Vera
- 1-CA4180P66K24E4Z整车-34C-译文Uploaded byArash Shams
- Paper1Uploaded byGurpreet Singh Dhindsa
- Aprilia ETV Mille - Rally Version Repair Manual UPDATE 2003-2004 EnglishUploaded bymartin_trumpet
- 0AMUploaded byPAULO
- Despiese y Partes Fuller RT-11710 BUploaded byFredy Rene Velazquez

- PurposeUploaded bybernabas
- PurposeUploaded bybernabas
- PurposeUploaded bybernabas
- Who is a leaderUploaded bybernabas
- Who is a leaderUploaded bybernabas
- Who is a leaderUploaded bybernabas
- Who is a leader.pptxUploaded bybernabas
- Who is a leaderUploaded bybernabas
- Who is a leaderUploaded bybernabas
- Who is a leaderUploaded bybernabas
- Who is a leaderUploaded bybernabas
- Who is a leaderUploaded bybernabas
- Who is a leaderUploaded bybernabas
- Who is a leaderUploaded bybernabas
- Who is a leaderUploaded bybernabas
- Who is a leader.pptxUploaded bybernabas
- Who is a leaderUploaded bybernabas
- Who is a leaderUploaded bybernabas
- Who is a leaderUploaded bybernabas
- Who is a leaderUploaded bybernabas
- Who is a leader.pptxUploaded bybernabas
- Who is a leaderUploaded bybernabas
- It ManagementUploaded bybernabas
- ManagementUploaded bybernabas
- ManagementUploaded bybernabas
- ManagementUploaded bybernabas
- ManagementUploaded bybernabas
- ManagementUploaded bybernabas
- ManagementUploaded bybernabas
- Result and DiscussionUploaded bybernabas

- Under Down UnderUploaded byTrex Treks
- DummyPfCtr1Uploaded bysivasivasap
- Cisco Router Configuration TutorialUploaded byShayne Maene
- Planet Hoppers 10Uploaded bySW-Fan
- BORANG C - English for FrontlinersUploaded byDamien Jombek
- GFCO Product - Ingredient List TemplateUploaded byokoko
- Draw a Lgt Form 09 Showing Estimate of Capital ExpenditureUploaded byKAYODE OLADIPUPO
- UntitledUploaded bysaintmaryspress
- Org-and-mgt-1[1].pptxUploaded byAngge Paglinawan
- Tales of Madness, Miracles, Death and SalvationUploaded byValentina Ferracioli
- ERP.pdfUploaded byminorona2409
- Problem SetUploaded bybaterbee
- Week 5 Money NarrativeUploaded byDiana Chita
- Imer Cement Mixer Workmanii250Uploaded byDouglas Allen Hughes Sr
- Lecture 5Uploaded byInactiveAccount
- Paper ACI Coupling Beams Canbolat-Parra-WightUploaded byOvidiu Cristian
- Manual Instalacion Bematech LS6000Uploaded byRafael Brett
- Allah and His Creation.pdfUploaded byrabtay
- A New Deformable Catenary Element for the Analysis of Cable Net Structures_2006Uploaded byTruong Viet Hung
- Intro Multimedia ReportUploaded byyasmin
- LC7218 PLL Frequency Synthesiser for Electronic Tuning in AV Systems DatasheetUploaded by57 varieties
- my preschool handbook colored copyUploaded byapi-263198218
- Instruction Manual ITE UKUploaded byPaul Kwong
- PMWHR Herd Management Area Plan and Environmental AssessmentUploaded byThe Blue-Green Marble
- Mollick (2014) the Dynamics of Crowdfunding - An Exploratory Study JOThe dynamics of cBVUploaded byJaap Woltjes
- Fireline RDX Cord TDSUploaded byW N Nan Fajar
- Morgan Essay - myth and propagandaUploaded bywulfstan1000
- gl_ii-3-3_eUploaded byAsif Hameed
- Section 5 Family Planning.docxUploaded byLaurenLiu
- ACB SparesUploaded byVikas Yadav