Professional Documents
Culture Documents
REPORT
SUBMITTED IN REQUIREMENT FOR
FOUR WEEK INDUSTRIAL TRAINING
AT
VE COMMERCIAL VEHICLES
DEWAS
SUBMITTED BY
AKSHAT R. JAIN
Mechanical Engineering
Univ Roll No (0201ME201006)
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ACKNOWLEDGEMENT
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TABLE OF CONTENTS
Introduction………………………………………………………………………………………………………..…6-9
Reference……………………………………………………………………………………………………………….22
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1.0 Introduction |
shafts/wheels when the center distance between the shafts is not too large. They
provide a positive drive, maintaining exact velocity ratios between driving and driven
shafts.
between the engine and driving wheels of the vehicle. It provides a means for
changing the ratio between engine rpm (revolutions per minutes) and driving wheel
rpm to best meet each particular driving situation. Given in order to get smooth
starts and have power to pass and climb hills, a power ratio must be provided to
multiply the torque and turning effort of the engine. Also required is a speed ration
to avoid the need for extremely high engine rpm at high road speed. The
Power transmission gears are usually made from chromium molybdenum steel
which provides good toughness and resistance to wear. Some (low power) gears are
made from sintered metal (powered metal). Non-power gears can be made of almost
any material including composites for quieter running non lubricated arrangements.
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1.1 Gears usage:
It plays an important role in our daily life basis, starting from our washing
machines in houses till the heavy vehicles in mining and construction places.
Accordingly for each machine or vehicle. Gears are simply a means of applying
leverage to rotating parts. A modern transmission provides both speeds and power.
The engineer who designed it selected the gear sizes that would give the best all
around performance. It is geared to a power ratio that puts the car in motion, and
then it shifts, or it shifted, to one or more speed ratios that keeps it rolling.
Different types of gearbox are used. These types are manual gear, automatic,
semi-automatic, and bicycle gearing. For each gearbox, several gears are utilized such
as spur, helical, bevel, hypoid and worm gears. Each type of gear is explained briefly
below:
• Spur Gear
accessory gearbox of an
engine. The gear can be Figure 1: Spur gears formed either internally or
required without changing the axis of drive. External spur gears are used
where a change in speed is required but the shafts lie parallel to each other.
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Spur gears may be noisy owing to the impact of the teeth upon each other
as they rotate.
Helical Gear
This is a smoother, less noisy running gear than the spur gear, the teeth are cut on a
curve or helix, which produces a sliding engagement of the teeth, and more than one
tooth is in engagement at any one time. A disadvantage of this gear for is that it
produces a heavy axial load. This disadvantage can be eliminated by using double
helical gears, with the teeth being cut in an opposite helix. An advantage of this type
of gear is that it can accept and transmit a higher loading than a spur gear of the
same size. Helical gears might be fitted in the reduction gearbox of a turbo prop
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Bevel Gear
This type of gear is used when the drive is required to be transmitted through an
angle; in this case the gear teeth can be straight cut or in a helical form, when the axis
of the shafts intersect. An example of use would be for the transmission of drive from
the main rotating assembly on a gas turbine to the accessory gearbox, or the tail rotor
gearbox on a helicopter.
Worm Gear
This gear form is used where there is a large resistance to turning, and a
large reduction in speed is required. The worm teeth are similar to a multi
start thread, and are cut at an angle or on the skew, in which case the gear
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Automatic gear box : An automatic transmission (also called
pawl feature that locks the output shaft of the transmission stroke
face to keep the vehicle from rolling either forward or backward. [2]
gear ratios. There are two main types: derailleur gears and hub gears.
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The derailleur type is the most common, and the most visible, using
sprocket gears. Typically there are several gears available on the rear
number of sprocket gears in front by the number to the rear gives the
of main shaft, counter shaft, and housing. Gears are placed in the
bearings to hold and support the shafts inside the housing. The
pistons to the car wheels. Owing to the gear ratios, gears such as
reverse gear, low gear, second gear, high gear, & overdrive rotate in
different rotational speeds. For example in high gear, the gear ratio is
crankshaft.
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2.0 Design Calculations and Drawings
The following table shows the gearbox components and their specifications:
Part List
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4 2nd gear 1 Steel
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7 4th gear 1 Steel
10 Countershaft 1 C.I.
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11 Countershaft gear 1 Steel
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14 Bearing 5 Steel
16 Housing 1 C.I
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3.0 Gearbox Operation |
The gearbox principle is based on receiving the motion from the piston,
where the clutch controls whether to connect the motion to the clutch gear or
not, and pass it through the main shaft. Within the main shaft, the arrangement
of the gears decides the passage of the motion, thus, leading to specific speed of
the drive gear. In our gearbox, 5 transmissions were found and explained as
follows:
3.1 First Gear: the clutch connects the motion to the clutch gear then to the counter
shaft which provides the motion to the 1 st gear input. Next, the 1st gear input causes
the 1st gear to rotate and thus leading to rotate the drive shaft. The 1 st gear diameter
is 30 mm which is relatively large. Though the large gear gives low speed, very large
gear, the counter shaft is directed to transmit the motion to the 2 nd gear
input, hence the 2nd gear rotates leading to the drive shaft to rotate with
2.4 to 1 gear ratio; . The 2nd gear diameter is 25 mm, less power
3.3 Third Gear: as dog clutch clutches the 3 rd gear of 20 mm in diameter, the
motion passes through the counter shaft leading to the drive shaft to gear
3.4 Fourth Gear: Owing to the straight pass of motion, the gear ratio of the 4 th
gear becomes 1 to 1; the driven gear is the same as the driving gear.
direction. This happens due to the reverse idler which exists between the
beginning of how to choose a gearbox till the end of how to assemble the parts
discovered that the gearbox was automatic and it had to be left and
another one had to be brought instead. 3 weeks were lost for this
problem.
such thing, little help was asked. However, wrong instructions were given
by the technicians. On the other hand, one student from another group
helped us and we got back on the right track. 2 weeks were spent for
disassembling.
For future improvements for the following batch that they should stick to
fully
understandable.
5.0 Appendix |
This figure shows the stress machine used to dislocate the case out of the
shaft:
[1] Lahue, K. C., Petersen's big book of auto repair, In-text: (Lahue, 1976.)