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Draw Power Train Block Diagram:

Power Train of D-85

Write The name of Direct type transmission:
 Slide mesh transmission : (D-50 , D-40)
 Constant mesh transmission : (D-60)
 Synchromesh transmission : (ISUZU Dump Truck)
 Selective Slide Transmission

Differentiate between dry and wet clutch:

Wet Type Clutch
A clutch when operates within an oil bath then it is called a wet clutch. Multidisc clutch are wet type clutch.
Dry Type Clutch
A dry clutch operates without oil. Single disc and double disc clutch are dry type clutch.
Define Springs:
Springs are elastic bodies (generally metal) that can be twisted, compressed or stretched by some force.
They can return to their original shape when the force is released

What is the compression spring?

The spring is designed to operate with a compression load, so the spring gets shorter as the load is applied to
it. Compression springs can be used in many applications, including:

 Engine Valves
 Electronics
 Mining and drilling equipment
 Pens or notebooks
 Toys
 Mattresses

What is Positive Clutch?

The positive clutches are used when positive (no slip) drives are required. These clutches transmit power
from the drive shaft to the driven shaft by the interlocking of jaws or teeth. They are rarely used as
compared to friction clutch.
What is Torsion Spring?
A torsion spring is a spring that works by torsion or twisting that is a flexible elastic object that stores
mechanical energy when it is twisted.

What is the function of over center system?

 Use to engage and disengage the main clutch
 To prevent the discs and plate from slipping

Define inertia brake system?

 It is use to stop the input shaft of transmission and easy gear shifting and less noisy.
 When the clutch is disengage, the rotation of input shaft of transmission is rotates due to inertia of
machine, it is necessary to stop the input shaft for prevent the inertia and stop the input shaft.
 When the clutch is engage the inertia brake will not be apply.
 When the clutch is disengage the inertia brake will be apply.

What is dog clutch?

 A dog clutch is a mechanism used to connect and disconnect two rotating shafts or machine parts.
 This clutch engages not by friction but by interference.
 It has the benefit of allowing both shafts to turn at the same speed without slipping.

Differentiate between constant mesh and synchromesh transmission?

Constant mesh transmission

In this transmission gears are always meshed with their partner gears but free on the shaft with the needle
bearings, we just need to engage the gears with the shaft. This is done by a using dog clutches. These
transmissions produce less noise as compared to the slide mesh transmission.

Synchromesh transmission

This transmission is similar to the that of constant mesh transmission only the difference is that in this
transmission dog clutches are replaced with synchronizing units. This is noise less transmission, because in
this transmission the speed of gear and the shaft is synchronized using different kind of synchronizing units
i.e. cone type, balk ring type, pin type, protuberance type synchronizing.
Define hydraulic booster?
Hydraulic booster reduces the operator effort for engagement or disengagement main clutch using hydraulic
oil. It increase the efficiency of clutch.

Define interlocking mechanism?

 It is use to prevent the gear from slipping.
 It is use to prevent the double meshing gear.

What are the functions of Torque converter?

 It transfer the power from engine to transmission input shaft.
 It multiplies the torque of the engine and transmits to the transmission.
 Torque converter is a kind of automatic transmission that can adjust power flow continuously not
stepwise.

Differentiate between fluid coupling and torque converter?

 Both are used for the same purpose- Power transmission, the basic difference is, a torque converter is
able to multiply torque, which a fluid coupling cannot.
 Torque converter has a stator and fluid coupling has no stator.

Define Spiral bevel gear?

 A spiral bevel gear is a bevel gear with helical teeth.
 The main application of this is in a vehicle differential, where the direction of drive from the drive
shaft must be turned 90 degrees to drive the wheels.

Differentiate between Helical and spur gear?

Helical gear

 The teeth of a helical gear are set at an angle

 In helical gears, multiple teeth are always in mesh, which means less load on
each individual tooth.
 Helical gears are used for high speed applications.
 Helical gears are less noisy and more efficient than normal spur gears.

Spur Gear

 Spur gears are a cylindrical shaped toothed component used in industrial equipment to transfer
mechanical motion as well as control speed, power, and torque.
 Spur gear are use for speed applications.
  Spur gears are used to transfer motion and power from one shaft to another shaft.
 Spur gear has staight teeths.
 It is used in transmission,conveyer system,speed reducers, engine and
mechanical transportation system gear pumps and motors.

Define Multi Disc Clutch?

This type of clutch has multiple clutch plates that are used to transmit power from the shaft of an engine to
the transmission shaft of the same vehicle.
What is cone clutch type synchronizing unit?
 Cone type synchronizing unit is the type of synchronizing unit used in synchromesh transmission.
 When the sleeve is moved using shifting fork, due to the spring loaded ball hub moves first. When
the hub’s external cone comes in contact with internal cone of side gear a frictional contact produce
due to which the velocities of two gears is equalize.

What is synchronizing unit?

Synchronizing units is used to equalize the speed of hub and sleeve with gear by removing difference of
speed.

Define pitch point of a gear?

The point from which pitch circle is passed, at which face and flank meet together.

What is the difference between friction clutch and positive clutch?

Positive Clutch

The positive clutches are used when positive (no slip) drives are required. These clutches transmit power
from the drive shaft to the driven shaft by the interlocking of jaws or teeth. They are rarely used as
compared to friction clutch.

Friction Clutch

They are the most frequently used type of clutch. A friction clutch transmits power by virtue of friction
developed between contacting surface. The friction surface is typically flat and perpendicular to the axis of
rotation. Two or more surface is pressed together by using compression spring.
 2016 Final Paper of DAE Mechanical

What is the purpose of transmission?

 The function of transmission is to provide torque and speed according to the road and load condition.
 To move the vehicle in reverse direction.
 With the help of transmission we can keep the engine in neutral condition.

Write down the name of Different types of transmission?

Write down the name of different types of gears?

 Spur gear
 Helical gear
 Rack and pinion type gear
 Bevel Gear
 Miter gear
 Screw Gear

Write down the name of different types of springs on the basis of their function?
 Leaf Spring.
 Spiral Spring.
 Flat Spring.
 Machined spring.
 Conical spring.
 Wave Spring.
 Coil Spring.
 Tension Spring.
 Compression Spring.
 Torsion Spring.
What is the advantage of synchromesh transmission?
 Smooth and noise-free gear shifting that is best suited for cars—no loss of torque transmission from engine to
driving wheels during a gear shift.
 Quick shifting of gears without risk of gear being damaged.

Why Balk ring is used?

 It has extra component the balk ring which is a ring with external teethes.
 The balk ring prevents the gears engaging before they are rotating at correct speeds. While engaging,
the ring will gradually slide into the cone and the friction will slow or speeds up the gear wheel. Finally, it
stabilizes the speed of synchronizer and gear and thus revolves at the same speed.

Differentiate between constant mesh and synchromesh transmission?

Constant mesh transmission

In this transmission gears are always meshed with their partner gears but free on the shaft with the needle
bearings, we just need to engage the gears with the shaft. This is done by a using dog clutches. These
transmissions produce less noise as compared to the slide mesh transmission.

Slide Mesh Transmission

In this type of transmission gears are slide on the shaft and meshed with the other gears. The shifting or
meshing of different gear ratios is done by the sliding of gears towards the right and left over the splined
shaft with the help of a gear lever operated by the driver.

Define Addendum?
 Distance between pitch circle and addendum circle is called addendum.
 Whole depth – Addendum circle = Addendum

Define Pitch Circle?

PITCH CIRCLE is the circle derived from a number of teeth and a specified diametral or circular pitch.
Circle on which spacing or tooth profiles is established and from which the tooth proportions are
constructed.

What is Diametral Pitch?

DIAMETRAL PITCH (P) is the ratio of the number of teeth to the pitch diameter.

What is the main function of hydraulic booster used in main clutch?

 Use to increase the clutch efficiency
 Use to decrease the operator fatigue

Describe Rack and pinion gear?

It is the type of gear. It have pinion and rack. The pinion
engaged with a rack, this type of gear is use to convert rotational
motion into linear motion. A rack and pinion drive can use
both straight and helical gears.
Function Of Dog Clutch
Dog Clutch is Used in Constant mesh transmission To Shifts The Different speeds/ Gears

What is Gear Ratio?

Gears are also used to achieve torque and speed according to the requirement. It is done
by driving a large gear (having more teeth) by a small gear (having less teeth) or vice
versa. This is called as gear ratio between two gears. It can also be described as the ratio
between the no of teeth of driven gear and the no of teeth of driver gear.

What is Dedendum?
 Distance between pitch circle and dedendum circle is called dedendum.
 Whole depth – Dedendum circle = Dedendum

What is the function of over center system in main clutch of D60?

 Use to engage and disengage the main clutch
 To prevent the discs and plate from slipping

What are factors affecting torque capacity of main clutch?

 Co-efficient of friction of material.
 Area of disc and plates (size of discs and plates)
 Pressure by spring on pressure plate.
 No of friction faces. (Quantity of discs and plates)

What is the Function of inertia brake system?

 It is use to stop the input shaft of transmission and easy gear shifting and less noisy.
 When the clutch is disengage, the rotation of input shaft of transmission is rotates due to inertia of
machine, it is necessary to stop the input shaft for prevent the inertia and stop the input shaft.
 When the clutch is engage the inertia brake will not be apply.
 When the clutch is disengage the inertia brake will be apply.

What is the function of balk ring?

The balk ring prevents the gears engaging before they are rotating at correct speeds. While engaging, the ring will
gradually slide into the cone and the friction will slow or speeds up the gear wheel. Finally, it stabilizes the speed of
synchronizer and gear and thus revolves at the same speed.

Define Transmission?
Transmission is a device which transmitted torque and speed according to the road and load condition. It is
done by the changing of gear ratio. It depends upon the size of gear.
Define circular pitch and diametral pitch?
Circular pitch

A circular pitch is the distance between the corresponding points of the adjacent teeth measured on the pitch
circle. In other words, it is the space between the teeth.

Diametral Pitch

DIAMETRAL PITCH (P) is the ratio of the number of teeth to the pitch diameter.

Write The shafts name in slide mesh transmission?

 Input shaft
 Main shaft
 Intermediate shaft
 Counter shaft

What are the disadvantages of helical gear?

 When a pair of helical gear meshes with each other, there will be creation of axial thrust load on gear
due to helix angle of gear teeth and therefore gearbox designer has to select such bearings those are
able to absorb and support this axial thrust load.
 There will be sliding movement between mating gear teeth in case of helical gear and heat generation
will be more as compared to spur gear application. Therefore helical gear requires good quality of
lubrication.
 One pair of mating helical gear will have less efficiency as compared to efficiency of mating spur
gears of similar size.
 Power loss in case of helical gear train operation will be more as compared to spur gear train
operation.
 Manufacturing and designing cost of helical gears will be more as compared to spur gear designing
and manufacturing cost.

Which gears can be used to transmit power in parallel shafts?

Helical gears could be used to transmit the motion and power between two parallel shafts and also between
two non parallel shafts.
Write down the name of different types of springs on the basis of their Constuction?
 Helical springs
 Leaf springs
 Disc springs

Function Of main clutch?

A clutch is a mechanical device that engages and disengages the power transmission means shaft especially
from the driving shaft to driven shaft. When we have to change the gear in the transmission system then for
that time we have to use the clutch.
Write the names of shafts in constant mesh transmission?
 Input shaft
 Main shaft
 Intermediate shaft
 Counter shaft

Draw backs/Disadvantages of slide mesh transmission:

 It takes more time and money to replace the gears if the gearbox fails.
 Less life of gear as more wear and tear of gear is caused in sliding mesh gearbox due to friction.
 More effort is required to engage the gear as the gear has to be slide in sliding mesh gearbox

Why Multidisc clutch are use?

It is used where high load and Power required. It is use to reduce wear and tear b/w disc and plate and to
reduce noise. Also reduces more friction.

Characteristics of slide mesh transmission:

 Since only one gear is in mesh in the sliding mesh gearbox so less fluctuating loads on shafts causing
less vibration and noise.
 Its efficiency is more than a constant gearbox.
 Its manufacturing is easy as compared to a constant mesh gearbox.

How does inertia brake works?

 When disengage the main clutch output shaft still rotates due to its inertia.
 During gear change, the speed difference can cause to strike of gears, produces noise cause troubles
and to prevent from speed change this inertia brake equipped.
 It constructed at output shaft of main clutch.
 When shifting lever thrown down first main clutch will disengaged by further thrown down the lever
this inertia brake will apply.
 Brake drum which is fixed to main clutch output shaft is bounded with brake band to prevent
revolution to ensure smooth transmission gear change.
 It equipped with all dozers e.g. D60-8, D50-17.

What is the Function of torque converter?

 It transfers the power from the engine to the transmission input shaft.
 It isolates the engine from the load when the vehicle is stationary.
 It multiplies the torque of the engine and transmits it to the transmission. It almost doubles the output
torque.
 Torque converter is a kind of automatic transmission that can adjust power flow continuously not
stepwise.
Explain the formula of torque multiplication?
 In torque converter pump accelerates the oil flow by force T3, Turbine decelerates oil flow by T1, the
stator changes direction of oil flow by T2.

T1 = T2 + T3
Turbine Force = Stator Force + Pump Force

 Due to slip turbine force varies 1to 4 times as large as input torque (Pump force), so turbine’s force
become 2.5 to 4 times greater as the pump force under heavy load.

Write the parts of fluid coupling?

 Turbine
 Pump
 Case
 Fluid

Write down the formula of slip ratio of fluid coupling

What do you know about the vanes of fluid coupling and torque converter?
 The vanes of fluid coupling are straight.
 The vanes of torque converter are curved.

What do you know about scavenging pump of torque converter?

 Scavenging pump keeps the suitability low oil level and transfer oil to torque flow transmission case
from torque converter case.
 It is gear type pump which driven by torque converter through gear at back side.
 It circulate oil to transmission case from torque converter case.

What do you know about stall speed of torque converter?

 It is called that the torque converter stalls when revolution of output shaft is reduced to zero,
regardless to revolution of input shaft.
 The speed at which engine fully throttle is stall speed just when torque converter stall.
 It increase when viscosity of oil is low and reduces when viscosity increase.
What is the function of ball check valve in rotary clutch pack in D-85?
 When clutch engaged ball check valve will be seated and piston exerts force on discs and plates to
engaged.
 But when stops the oil pressure/flow the ball check valve will leave its seat and due to escape from
small place at its seat to the transmission case.
 So that piston returns immediately and 2nd, 3rd clutch can be engaged.
 Otherwise 1st speed clutch can’t be disengaged and impossible to change gear.
 So to prevent from this ball check valve installed for immediately return of piston.

What is Cantilever spring?

A flat spring supported at one end and holding a load at or near the other end.

What is the grade of oil used in torque converter of D65?

SAE-30

What is spiral bevel gear?

Spiral bevel gears have curved teeth that contact each other gradually and smoothly from one end of the
tooth to the other. Spiral bevel gears are smoother and quieter in operation than straight bevel gears, in this
type of gear two or more teeth are contact with each other.

Write the name of any four types of springs?

 Helical spring
 Leaf spring
 Wave spring
 Conical spring

Define Gear?
 Gear is the component that is use to transmit the power from one shaft to another shaft.
 A wheel with teeth around its rim that mesh with the teeth of another wheel to transmit motion
 The best example of gear is transmission assembly. In transmission there are different size of gear
are present to change the speed of vehicle, and increase and decrease the torque of vehicle.
What is the compression spring and where it use?
The spring is designed to operate with a compression load, so the spring gets shorter as the load is applied to
it. Compression springs can be used in many applications, including:

 Engine Valves
 Electronics
 Mining and drilling equipment
 Pens or notebooks
 Toys
 Mattresses

What is main clutch?

A clutch is a mechanical device that engages and disengages the power transmission means shaft especially
from the driving shaft to driven shaft. When we have to change the gear in the transmission system then for
that time we have to use the clutch.
Define any two gears?
Helical gear

 The teeth of a helical gear are set at an angle

 In helical gears, multiple teeth are always in mesh, which means less load on
each individual tooth.
 Helical gears are used to provide high speed.
 Helical gears are less noisy and more efficient than normal spur gears.

Spur Gear

 Spur gears are a cylindrical shaped toothed component used in industrial equipment to transfer
mechanical motion as well as control speed, power, and torque.
 Spur gear are use to provide high torque.
 Spur gears are used to transfer motion and power from one shaft to another shaft.
 Spur gear has staight teeths.
 It is used in transmission,conveyer system,speed reducers, engine and
mechanical transportation system gear pumps and motors.

Define Worm Gear?

 A worm gear is a gear consisting of a shaft with a spiral thread that engages with a toothed wheel.
 Worm gears are constructed of a worm and a gear (worm wheel), with non-parallel, non-intersecting
shafts oriented 90 degrees to each other.
Differentiate between Direct and indirect transmission?
Direct Type Transmission

In direct drive transmission the power of engine transmit to transmission directly by clutch.

Indirect Drive Transmission

In indirect drive transmission the power of engine transmit to transmission indirectly through torque
converter.

Write the types of synchronizing units?

 Cone type
 Balk ring type
 Protuberance type
 Pin type

Define selective slide Transmission?

An oldest and simplest type of transmission is selective slide transmission, in which gears slides length wise
on the shaft to come into engagement from its structural feathers.

What is the function of pump in fluid coupling?

 Pump is the component of fluid coupling.
 Fluid is sealed in pump and turbine.
 The pump driven by engine at high speed as it rotates it drives the fluid.
 Turbine is rotate by the force of fluid.

State Hook’s Law

The strain produced in a body by the stress apllied to it directly proportional to the stress with in the elastic
limit of the body.

Stress / Strain = Constant

Stress = Constant X Strain

What are the basic principle of fluid dynamics?

 The force becomes greater as fluid flow speed increase.
 The force becomes greater as density of fluid increase.
 The force becomes greater as fluid flow rate increase.
 The force becomes greater as the angle of incidence lower/smaller

What is the function of modulating valve?

The function of modulating valve is to prevent abrupt rising of oil pressure can applied to a clutch when gear
shifting level shifted.
What is Speed valve?
Speed valve feeds oil into specified clutch so that desire traveling can achieve.

Write the name of control valve upper body of D85?

 Modulating relief valve
 Reducing valve
 Quick return valve

What is the function of regulator valve in torque converter in the circuit of D65?
 Regulator valve keeps the torque convertor full of oil at 2-4 kg/cm2 maintaining pressure.
 The heat oil will be cooled by flowing through regulator and coolant.

Why stator is employed in torque convertor?

To prevent from bounce back of oil.

What is meant by under drive and over drive?

Under Drive

The speed of output shaft is less than the input shaft is called under drive.

Over Drive

The speed of input shaft is less than the output shaft is called under drive.

Teeth of driver gear is 12 and driven gear is 24 describe gear ratio?

Teeth of driver gear = 12

Teeth of driven gear = 24

Gear ratio = ?

Formula:-

Gear ratio = 24/12

Gear ratio = 2

Explain the reverse 1st speed of constant mesh transmission?

What is leaf spring?
 A leaf spring is a simple form of spring commonly used for the suspension in wheeled vehicles.
 A spring made of a number of strips of metal curved slightly upward and clamped together one
above the other.

What is fluid Coupling?

Fluid coupling is a form of clutch which transmit the power from engine to transmission with help of fluid.

Parts

 Turbine
 Pump
 Case
 Fluid

What is 2-phase torque converter?

A torque converter has one pump, one turbine and one stator which is allowable to rotate in only one
direction. This type of torque converter is called as 2 phase single stage, 3element torque converter

What is the function of stator in torque converter?

 Stator is use to increase the angle of incidence of oil to the pump blade.
 It basically removed the issue of bounce back due to which slip can’t occurs but stator removed that
issue.

What is the reasons of clutch slipping?

 Wear of discs and plates.
 Pressure plate springs are broken.
 Adjustment of clutch is not proper.
 Adjustment of lever is not proper.

What is tension spring and where it is use?

The spring is designed to operate with a tension load, so the spring stretches as the load is applied to it.
What is the function of pump in torque converter?
 This component is attached to the engine’s crankshaft. It also spins with it all the time. When the impeller
starts to spin, it catches the transmission fluid. The generated centrifugal force moves the fluid to the edges of
the pump.

 The force with which the fluid moves depends on the speed at which the impeller spins. The turbine -which
also spins- receives the fluid from the impeller.