T-Rex Motorsports

Department of Powertrain
1) Pitch Circle Diameter

D= P/ sin(180/Z)

D= 15.88/ sin(180/45)

D= 227.577mm

1. Top Diameter

Dmax=D+1.25p-d1 = 227.577+1.25x15.88-10.16

Dmax=237.261mm

Dmin= D+P(1-(1.6/Z))-d = 227.577+15.88(1-(1.6/45))-10.16

Dmin=232.728 mm
T-REX MOTORSPORTS 1

2. Root Diameter

Df=D-2ri

rimax= 0.505d1+0.069(di)(1/3) = 0.505x10.16+0.069(10.16)(1/3)

rimax=5.280244mm

rimin=0.505d1=0.505x10.16

rimin=5.1308mm

Therefore,

Dfmax= 227.577-2x5.280244

Dfmax=217.0165mm

Dfmin=227.577-2x5.1308

Department of Powertrain
Dfmin=217.3154mm

3. Tooth Flank Radius (re)

(re)max=0.008d1(Z2+180)=0.008x10.16(452+180)

(re)max=179.22 mm

(re)min=0.12d1(Z+2)=0.12x10.16(45+2)

(re)min=80.4672mm

4. Roller Setting angle(α)

αmax= (120-(90/Z))=120-(90/45)

αmax= 1180

αmin=140-(90/Z) =140-(90/45)

αmin=1380

5. Tooth Height above the pitch polygon(ha)

T-REX MOTORSPORTS 2

(ha)max=0.625p-0.5d1+(0.8xp/Z)=0.625x15.88-0.5x10.16+(0.8x15.88/45)

(ha)max=5.1241mm

(ha)min=0.5(p-d1)=0.5x(15.8810.16)

(ha)min=2.8575mm

6. Tooth side radius(rx)

(rx)min=p=15.88mm

Department of Powertrain
Design of Turnbuckle

T-REX MOTORSPORTS 3

1. Selection of Material

 Grey Cast iron FG200 (Sut=200 N/mm2) for coupler.

 Plain carbon steel of 30c8 (Syt=400 N.mm2) for rods.

2. Factor of Safety

Factor of safety is 5 for design.

3. Rod Diameter

Pdm µsec Ꝋ +tanα

Mt= ×
2 (1−µsec Ꝋ . tanα)

Where dm=0.9d
µ=0.15

Department of Powertrain
 Ꝋ=300
α=2.50

2414.8462 ×0.9 d 0.15 sec 30+tan 2.5

650= ×
2 (1−0.15 sec30 . tan 2.5)

Therefore,

dc= 3.42 mm

Hence Selecting rod of 8mm diameter.

T-REX MOTORSPORTS 4

Torque and Speed

Since,

N1 T 2
=
N2 T1

Department of Powertrain
 7500 82
=
N 2 44

N2= 4026 rpm

1) For 1st Gear

4026 41
=
N 2 14

N2=1376 rpm

2) For 2nd gear

4026 33
=
N 2 16
T-REX MOTORSPORTS 5
N2=1952 rpm

3) For 3rd gear

4026 28
=
N 2 16

N2=2446 rpm

4) For 4th gear

4026 26
=
N 2 19

N2=2944 rpm

5) For 5th gear

4026 24
=
N 2 20

Department of Powertrain
 N2=3355 rpm

6) For 6th gear

4026 25
=
N 2 23

N2=3704 rpm

By final drive ratio 1:3

1st = 459rpm

2nd = 657 rpm

3rd = 816rpm

4th =982 rpm

5thT-REX
=1119rpm
MOTORSPORTS 6
th
6 =1235rpm

Speed in Km/Hr

1st = 45.85Kmph

2nd = 65.63Kmph

3rd = 81.52Kmph

4th =98.11Kmph

5th=111.79Kmph

6th=123.4Kmph

Department of Powertrain
T-REX MOTORSPORTS 7

Department of Powertrain