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Design and Calculation of Five Speed Manual

Gear-Box
(LANDCRUISER)
Zaw Zaw Lwin(u), Dr. Htay Htay Win
Abstract----- In this paper, power transmission system for power of the engine to meet changing road and load
landcruiser is designed. Power transmission system for automobile conditions.
is composed of transmission gear box, universal joint and There are two types of transmission, namely,
propeller shaft, final differential and wheel axles. The transmission
manual transmission and automatic transmission. Manual
gear box is placed just after the clutch and transmits power from
transmission type is used for so many cars in various
clutch shaft to propeller shaft. The transmission consists of a train
models and locations. If the car has a manual gear box, the
of gears of different sizes contained in a case. The automobile
transmission provides three, four or more forward gear ratio and driver moves the shift lever to shift gears. Automatic
reverse. This thesis emphasizes on the design calculation of five gearbox does the job automatically without any effort by the
speed manual gear box for landcruiser which has just five forward driver. Manual transmission consists of a cast iron or
gear ratio and reverse.This gear box is designed to transmit the aluminum housing, shafts, bearings, gears, synchronizing
power of 1HD-T engine. The engine maximum power is 121 kW at devices and shifting mechanisms. Automatic transmission
3600 rpm and maximum torque of 360 Nm at 2100 rpm. In this includes a torque converter, compound planetary gear set,
paper, the design procedures of gear pairs and shafts are included
two or more disc clutches and one or more bands. The
and the calculation results are also expressed. The analyzing and
scope of the research and thesis area is to design and
designing of gears and shafts design for five speed gear box are
fabrication of four-wheel drive five speed manual gear box
described.
for 1 HD-T engine as shown in Fig. 1.
Keywords: transmission, gear box, gear, number of teeth,
shaft, shaft diameter

1. INTRODUCTION
All form of motorized transport, including vessels
and aircraft, need transmissions to convert torque and
rotation. The average engine would have power enough to
operate a car without a transmission provided the car
operated on reasonably level roads and maintained
Figure 1. H151F Type of Manual Transmission
sufficient speed. When the car must be started from a
standstill, or when attempting to negotiate steep grades, the 2. THE MAIN COMPONENTS OF GEARBOX
engine would not provided sufficient power and the car A typical transmission consists of housing, shafts,
would stall. Much less torque is required to move a car bearings, gears, synchronizing devices and shifting
rolling on level ground than is necessary to drive the same mechanisms. Shafts and bearings are related in their relative
car up a steep hill. To enable the engine to increase torque positions in the housing. The gearbox of 1 HD-T engine has
to the drive line, it is obvious that a torque multiplier four shafts and thirteen helical for forward and reverse
(transmission) is needed. The history of the development of speeds. Transmissions are generally equipped with helical
vehicle transmissions can be divided into four stages. By gears to assure longer life, quieter operation and improving
using a transmission, it is possible to adapt the available efficiency. All gears may be of constant mesh design. A
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synchromesh unit is designed to provide smooth gear
shifting without clashing or grinding. Helical gears are used
throughout and each gear on the main shaft is supported on
needle rollers. Helical gears attached with dog teeth are
used as double gear and the use of needle rollers also
reduces noise and improves efficiency. The transmission
consists of the input (clutch) and output (main) shaft
assemblies, the counter gear and reverse idler assembly. All
are housed in a strong steel or aluminum housing.
4.1. Neutral Position
The power trend in neutral position is as shown in
Fig. 2. No power is flowing through the transmission main
shaft and the car is stationary. When the clutch is engaged
and the engine is running, the clutch shaft gear drives the
counter shaft driven gear.. In this position, the transmitted
power from engine output passes through the clutch shaft or
input shaft of gearbox and then directly through fourth gear
or main drive gear on counter shaft.

3. THE MANUL GEARBOX

3rd-4th
Most people who drive will be able to describe 1st-2nd
Clu 5th
some aspects of one of these. As the name suggests, the G
tch
G G GG G
driver has to change between one gear ratio and another, as
the vehicle requires, when using this type of gearbox. The In Ou
pu tpu
different gears have different ratios that allow different
←
relative speeds between the engine and road wheels. There Idler
are several distinct types of these transmissions; including
G
‘transverse’ or ‘transaxle’ front wheel drive gearboxes and
Counter G G G
‘inline’ gearboxes used in rear and four wheel dive vehicles. G
Four wheel drive vehicles will have an additional G G
transmission unit on the rear of the gearbox to enable the Figure 2. Neutral Position of Gear Mesh
drive of both front and rear axles.
5. LITERATURE REVIEWON GEAR TRAIN

3.1. Uses of Manual Gearbox Gear is defined as a machine element used to

transmit motion and power between rotating shafts by
Inline gearboxes are used in a wide range of vehicles
means of progressive engagement of projections called
from small passenger cars up to large trucks, while the vast
teeth. Gears are widely used for transmitting small or large
majority of transverse gearboxes are used in passenger cars and
amount of power from one shaft to another. Generally, spur,
small vans. It should be noted that manual gearboxes are
helical, warm and bevel gears are most commonly used in
nowhere near as common in the US and Japanese passenger car
industry for power transmission purpose. Among them,
markets as they are in Europe. This is particularly the case
helical gear is used in this transmission gear box.
with small to medium cars. In the past, the majority of larger
passenger and commercial vehicles in Europe used manual 5.1. Gear Train
gearboxes of one type or another. This particular area of the A gear train is one or more pairs of gears operating
market is changing and becoming dominated by automatic
together to transmit power. Normally there is a speed
transmissions.
change from one to the next due to the different size of the
gears in mesh.
4. OPERATION OF GEARBOX
The velocity ratio (V.R) is defined as the ratio of
The five speed manual gearbox for 1 HD-T engine
the rotational speed of the input gear to that of the output
provides five forward speeds and one reverse, and the
operations are as follows. gear for a single pair of gears. It is inversely proportional to
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the number of teeth on the two gears, and for the spur gears 2M t
Sall = (9)
it is also inversely proportional to the pitch diameter. kyπ n m3 cos ψ
2

ωp Np ng Dg 5.3.1 Allowable Stress

V.R = = = = (1)
ωg Ng np Dp The allowable stress for gear tooth design depends
on the selected material and pitch line velocity (v).

5.2. Force on Gear Teeth For helical gear, the allowable stress for all pith line velocity

To understand the method of computing stresses in is calculated by:

gear teeth, it is helpful to consider the way power is  5 .6 

sall = So×   (10)
transmitted by a gear system. Power is received from engine  5 .6 + V 
by the clutch shaft rotating at engine speed. Thus there is a
torque in the shaft that can be computed from the following 5.4 Endurance Tooth Load
equation: The endurance load (Fo) is based on the Lewis

Power equation without a velocity factor. The endurance load is

Torque = (2)
Rotational Speed calculated by the following equations.
Fo = So B y π m cos ψ (11)

The pitch line velocity is derived from the basic The limited endurance load must be equal to or greater than

relationship, v = R ω, for a point moving in a circle. dynamic load (Fd).

πD p N p
v= (3) 5.5 Wear Tooth Load – Buckingham Equation
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Tangential Force To insure the durability of a gear pair, the tooth

Mt profiles must not have excessive contact stress as

Ft = (4)
( D p / 2) determined by the wear load Fw.

Radial Force Dp B K w Q
Fw= (12)
Fr = Ft tan Φ (5) cos 2 ψ
Normal Force
Ft 6. POWER TRANSMISSION SHAFT
Fn = (6) In transmission gear box, clutch shaft, counter
cos φn cos ψ
shaft, main shaft and idler shaft are used as the rotation
Axial Force
element to transmit the power of engine to drive axles. AISI
Fa = Ft tan ψ (7)
4150 OQT 1000 is used for the input shaft, output shaft and
main shaft material. Using this shaft material has ultimate
5.3. Stresses in Gear Teeth
strength 1360 MN/m2 and yield strength 1250 MN/m2 and
In the design of a gear for strength, the pitch
modulus of elasticity is 207 GN/m2. All shafts of the gear
diameter is either known or unknown. If the pitch diameter
box transmit the engine power to the rest of the transmission
is known, the following form of the Lewis equation may be
line. The ASME Code equations are described as follows.
used.
For a solid shaft with axial loading, the Code equation is:
For helical gear,
σ Fa d 
2

 K b M b + 8  + (K t M t )
 1  Sall kπ 2 16
d3 =
2
(13)
 m2 y  = cos ψ (8) πSs
  all Ft
For a solid shaft having little or no axial loading, the Code
If the pitch diameter is unknown, the following form of the
equation reduces to:
Lewis' equation may be used.
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Table 7.2. Results of Shaft Design
d3 =
16
(K b M b )2 + (K t + M t )2 (14)
πSs Sy
Type of Su Dia Length
7. RESULTSOF GEAR DATA Material
Shaft (MPa) (mm) (mm)
In the gear design calculation, AISI 4150 OQT (MPa)
1000 material was chosen. The material has brinell hardness Input 4150
1360 1250 21 244
401, yield stress 1250 MPa and ultimate stress 1360 MPa. Shaft OQT1000

For the forward speed gears, the design condition was Main 4150
1360 1250 30 326
unsatisfied with this brinell hardness values. So, the material Shaft OQT1000

was necessary to make heat treatment to get BHN 601. Counter 4150
1360 1250 24 358
Shaft OQT1000
Table 7.1.Result of Gear Mesh
Idler 4150
No. Heli Widt Spee 1360 1250 26 110
Modul Shaft OQT1000
Gear of Diamet x h d
e
Mesh Teet er (mm) Angl (mm (rpm 8.CONCLUSIONS
(mm) 0
h e( ) ) ) In the design of manual gear box for power
34 85 2.5 30 33 3600 transmission system of 1 HD-T engine, gear design and
Drive
44 111 2.5 30 33 2742 shaft design are considered. Thirteen helical gears are used
for forward and reverse speed.
First 19 68 3.5 23 35 2742
After knowing the gear ratio of the gear box, the
speed 37 129 3.5 23 35 1528
number of teeth of gears and gear parameter are specified.
Secon 20 70 3.5 30 33 2742
And then, the gear design is carried out. Gear design is
d
36 126 3.5 30 33 1443 based on the material used and parameter of gear. AISI 4150
speed OQT 1000 is used as the gear material and shaft material.
Third 33 91 2.75 30 25 1742 The ultimate tensile strength of this material is 1360 MPa,
speed 38 105 2.75 30 25 2369 the allowable static stress of the gear material is 1250 MPa,
Fifth 32 79 2.5 30 27 2742 and the brinell hardness number of this material is 401. The
speed 47 117 2.5 30 27 1828 beam strength of the gear teeth is determined from Lewis

Revers 13 48 2.75 23 70 2742 equation. In this design, beam strength induced in all gears
is less than allowable static stress. Therefore, this material is
e 29 96 2.75 23 70 1371
proper. And then, the gear design is calculated. All gears
speed 43 114 2.75 23 70 914
teeth of transmission gear box must have sufficient strength
In manual transmission, shafts are also the
and they will not fail under static loading or dynamic
important parts of the design portion. The shafts are
loading during normal operation. Therefore, the wear
designed according to the point of view of the strength and
characteristic and the endurance limit of the gear material
critical speed. Shafts are designed with 4150 OQT 1000 heat are considered in this gear design.
treated alloy steel. In the strength shaft design, by using the The wear tooth load and static tooth load of all gear
ASME code equation, the shaft diameters for variety of pairs are greater than the dynamic tooth load of the gear.
speed have to be calculated. In selecting the shaft diameter, Therefore, the gear design is satisfactory. The shaft is
the maximum value has the most safety effect although the designed according to the point of view of the strength. In
compactness and redesigning. Therefore, the maximum the strength shaft design, the shaft diameters for variety of
shaft diameters can be chosen. speeds have to be calculated by using the ASME code

The calculated specifications of shaft diameters are as equation. Diameters of out put, counter, idler and input shaft

followed in Table 7.2. are 30, 24, 36 and 21 mm respectively. There is small
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difference between the calculated results and existing ones.
It is due to different material.

9. REFERENCES
[1] Newton, K., W Steeds: The Motor Vehicle, 13th Ed.,
Reed Educational and ProfessionalPublishing Ltd.,
England, (2001)
[2] Gisbert Lechner and Harald Naunheimer: Automotive
Transmissions,1stEd.,Springer-Verlag Berlin
Heideberg, New York, (1999).
[3] William H. Crouse: Automotive Mechanics,
9th Ed., Tata Mc Graw.HillPublishing Company.
Ltd., (1985).
[4] Hall, Holowenko and Laughlin: Theory and
Problems of Machine Design, Mc Graw Hill Book
Company, (1982).
[5] Martin W. Stockel: Auto mechanics Fundamental,
1st Ed.,(1969).
[6] Robert L. Mott, P.E, 1985. “Machine Elements in
Mechanical Design”, Charles E. Merrill
Publishing Company.
[7] Martin W. Stockel, 1974. “Auto Mechanics
Fundamentals”, South Holland, Illinois,
Goodheart-Willcox Co., Inc.
[8] Hall, Hollow enho, Laughlin, 1961. “Theory and
Problems of Machine Design”, SOS series
Schoum Publising Co; New York.
[9] Giri, N.K. 2001. “Automobile Mechanics”,
Seventh Edition, Romesh Chander Khanna
Publishing Company, Nai Sarak, New Delhi, India
. [10] Alec, S. 1992. “Manual Gearbox Design”, Society
of Automotive Engineers, Butterworth,
Heinemann.
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