CHAPTER 5

DISCUSSIONS, CONCLUSION AND RECOMMENDATIONS

5.1. Discussions and Conclusion

In this thesis, the design analysis of OKA-05 five speed manual gearbox is
described. In this gearbox, there are all together five forward speed and one reverse.
Two types of gears are used in this transmission: spur and helical gear. Helical gears
are used for forward speed and spur gear drive is used for reverse speed.
Gears and shafts are designed with 6150 OQT400 heat treated alloy steel,
which has brinell hardness of 601, yield stress of 1860 Mpa and ultimate stress of
2170 Mpa. The required design calculation of spur and helical gears are calculated
through strength, dynamic and wear check. The shafts are designed according to the
strength point of view. In the shaft design, the shaft diameters for variety of speeds
have been calculated by using the ASME code equation.
The calculation design of counter and output shafts are based on maximum
tangential load at 1st speed gear position. The calculated diameters for each shaft are
20 mm for input shaft, 28 mm for counter shaft and 31 mm for output shaft. Finally,
the results from design calculation are also compared with existing design and the
calculated data are quite the same with existing data.
The bearings for OKA-05 gearbox are selected based on basic dynamic load
capacity. The design bearing life of machine is assumed to be 12,000 working hours.
Single row deep groove ball bearing is chosen for the input and output shaft. And,
taper roller bearing is selected for the counter shaft.

5.2. Recommendations
In designing of gear, the failures of scoring, corrosion wear and abrasive wear
are not considered in this thesis. It should be considered for gear design complement.
Moreover, the material selected for gears should be strong to prevent tooth breakage
and hard to resist the contact stresses and shock loads imposed on the gears. The
material used for shafts should have high strength, good machinability, high wear
 75

resistance and good heat treatment. In addition, for the hub sleeve ring gears,
synchronizer cone and the synchronizer ring design should be analyzed as
continuation work. Finally, this thesis can be suggested for the consideration and
design calculation of gears and shafts to have the particular requirement of any five
speed manual gearboxes.