1- The calculation of the synchronizer capacity of the gearbox

In this report, the parameters synchronizer design, including work and friction power, relative
linear speed and surface pressure, which are effective in determining the amount of wear and life of
this part, have been calculated. The prerequisites needed to calculate the design parameters
include gearbox conversion ratio, reflex moment of inertia, speed changes in the synchronizing
process, and geometric characteristics of the brass gear. The main purpose of this report is to
determine the amount of loading on the brass gear of the Arisan gearbox, and by examining the
increase in the effective surface of the cone by the double or triple mechanism, the amount of
loading has been compared in each case. These values were also calculated for ------, -------- and
----------- gearboxes, and considering that the same brass gear is used in each of these gearboxes,
the amount of loadings in Arisan gearbox in three brass gear models, single and double And Triple
has been compared with other gearboxes (-------------------------------) with the aim of investigating
the effect of loading during the lifetime of the part.

1-1 transmission gear ratio

The gear ratio of the gearbox is an important parameter in determining the value of the moment of
inertia and the speed difference in the synchronization process. In Table 1, this quantity is
presented for Arisan family gearboxes.

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--------- --------- --------- --------- Gear
4.11 3.35 3.37 4.36 1
2.33 2.14 2.11 2.46 2
1.52 1.39 1.38 1.46 3
1 1 1 1 4
- - 0.8 0.84 5
1.58 1.45 1.45 1.72 differential

1-2 moment of inertia

The amount of reflex inertia that is effective in the synchronization process is calculated by the
relation IR = ∑ In RG2 according to the gear ratio and moment of inertia of each of the gearbox
components specified in Table 2 and shown in Table 3. In this relationship, I R is the moment of
inertia of the reflex, In is the moment of inertia of each component, and RG is the gear ratio.

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Moment of
Gear Part
inertia(Kgm2)
 0.0004 Input shaft
0.0011 middle shaft
0.0026 First Gear
0.0007 Second gear
0.0037 Third Gear
0.0051 Clutch

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--------- --------- --------- --------- ---------

0.1329 0.0940 0.0955 0.1504 1

0.0429 0.0384 0.0374 0.0479 2
0.0181 0.0162 0.0160 0.0169 3
0.0079 0.0084 0.0084 0.0079 4
- - 0.0177 0.0235 5

1-3 Speed change during gear shifting

At the time of gear change, the synchronization system is responsible for synchronizing the gear
wheel and the related inertia set with the output shaft. The amount of revolution difference in each
gear change is proportional to the conversion ratio of each gear. which is calculated in table 4 in
two gear shifting modes. All calculations have been done for forward gear change at 3500 rpm and
for reverse gear change at 2100 rpm for vans and 1800 rpm for passenger car gearboxes.

-------------------------------------------------------------------------------------------------------
-------------------------------------------------------------------------------
--------------------------------------------------------------------------------------
--------------------
-------------------- -------------------- -------------------- --------------------

649.05 590.74 620.19 620.01 to 2 1

807.41 882.47 877.46 974.50 to 3 2
1190.97 982.01 963.77 1102.74 to 4 3
875.00 666.67 to 5 4
UP SHIFT Down

484.45 453.84 451.27 584.70 to 2 3

714.58 505.04 495.65 661.64 to 3 4
Shift

450.00 400.00 to 4 5

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------------------ ------------------- ------------------- --------------------

6.78 5.88 5.93 7.22 Nutral to 1
5.82 4.74 4.86 6.21 to 2 1
3.06 2.99 2.94 3.44 to 3 2
1.97 1.72 1.70 1.83 to 4 3
UP SHIFT

‫ـ‬ ‫ـ‬ 3.24 3.27 to 5 4

4.35 3.65 3.54 4.19 to 2 3

2.71 1.71 1.66 1.67 to 3 4
Shift
Down

‫ـ‬ ‫ـ‬ 0.79 0.47 to 4 5

1-4 Geometric parameters of synchronizer

In this section, the geometric characteristics of the brass gear to calculate the torque value of the
cone are specified in Table 5. In these calculations, the friction coefficient of the friction surfaces of
the brass gear is assumed to be 0.1.

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---------------- ---------------- ‫پارامتر‬
29.1 ---------------- Average Cone Radius (R)
7 ---------------- cone angle
0.1 ---------------- Friction coefficient of cone and chamfer
181 ---------------- Effective area of the cone (A)

1-5 Design parameters

Four parameters of shifting force, relative linear speed, specific friction power and surface
pressure of the cone have been compared in the existing conditions for the Arisan gearbox in three
synchronized mechanisms: single (effective area of cone 181 square mm), double (260 mm square)
and triple (400 mm square). Also, the mentioned design parameters for Roa 28, Pikan and Pikan
Vant gearboxes have been calculated, and compared with the values of design parameters in
Arisan gearbox in a graph.
 In Figure 1, the shifting force is calculated and shown. The amount of shifting force in Roa and
Pikan gearboxes is about 30% less than Arisan, and when double mechanism is used for Arisan
synchronization system, the amount of shifting force decreases by more than 30% compared to
single mode, and it decreases by about 60% for triple mechanism.

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053
59.233

003
35.682
91.482

052
93.842
13.642

01.442
27.012

002
15.302
19.891
33.181

36.851

051

00.151
69.631

06.531
24.821
63.521
71.321
78.711

001
93.001

65.59
)N( ecrof gnitfihS

12.48

54.28
02.27
40.17
52.56

21.26
05
92.35
46.43
0
1 ot N 2 ot 1 3 ot 2 4 ot 3 5 ot 4
gnitfihs raeG
)elgnis( nusirA )elbuod( nusirA )elpirT( nusirA 82aoR nakyaP
nakyaP pukciP
---------------------------------------------------------------------------------------------
006
30.045

005
43.454

004
77.143

003
12.072
99.662
86.052
51.222

002
02.281
10.171
)N( ecrof gnitfihS

28.251
80.841

66.311
51.111

001
07.701

47.17
75.96
61.86
03.44

71.33
55.03
33.91
75.21

0
1 ot 2 2 ot 3 3 ot 4 4 ot 5
gnitfihs raeG
)elgnis( nusirA )elbuod( nusirA )elpirT( nusirA 82aoR nakyaP
nakyaP pukciP

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 In Figure 2, the linear speed of sliding is calculated from the equation (V=R C ∆ω). One of the most
important parameters affecting wear is the sliding speed, and as can be seen in Arisan, it is greater
than Rua and Pikan in most gear changes, especially in reverse. This parameter is calculated in the
double and triple synchronization system for the outer ring, which is its maximum value.

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36.3
5.3 63.3
79.2
3

99.2
49.2
96.2
76.2

76.2
5.2

64.2
30.2
2 98.1
89.1
98.1
08.1

5.1

1
07.0
19.0
09.0

47.0
)s/m( yticolev gnidilS

5.0

0
1 ot N 2 ot 1 3 ot 2 4 ot 3 5 ot 4
gnitfihs raeG
)elgnis( nusirA )elbuod( nusirA )elpirT( nusirA 82aoR nakyaP
nakyaP pukciP

---------------------------------------------------------------------------------------------

5.2
81.2

20.2
2
87.1

5.1
45.1
15.1
84.1
83.1
73.1

73.1

22.1
31.1
91.1

1
79.0
39.0

5.0
)s/m( yticolev evitaleR

0
1 ot 2 2 ot 3 3 ot 4 4 ot 5
gnitfihs raeG
)elgnis( nusirA )elbuod( nusirA )elpirT( nusirA 82aoR nakyaP
nakyaP pukciP

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 In Figure 3, the specific friction power is calculated from the relation (P=W/(∆t.A)). In forward gear
shifting, the friction power of the brass gear in Arisan has increased by about 17% compared to
Pikan and Roa, but in reverse gear shifting, the synchronizing power has increased by about 90%
compared to Roa. As shown in the figure, the friction power in the double and triple mechanism is
reduced by about 40% and 60%, respectively.

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9

89.7

73.7
7

50.5
04.4

81.4

4
69.3
97.3
86.3

95.3
75.3

24.3
83.3

03.3

82.3
3

00.3
69.2
87.2

46.2

71.2
2
18.1

27.1

14.1
1
35.0

15.0
15.0
84.0
33.0
22.0

0
1 ot N 2 ot 1 3 ot 2 4 ot 3 5 ot 4
)2mm/W( rewop noitcirf cificepS

gnitfihs raeG
)elgnis( nusirA )elbuod( nusirA )elpirT( nusirA 82aoR nakyaP
nakyaP pukciP

---------------------------------------------------------------------------------------------
6

5
79.4

34.4

72.4

4
51.3

3
78.2

37.2
07.2

36.2
65.2
83.2

52.2
12.2

2
50.2

67.1

66.1

35.1
94.1

1
80.1

79.0

39.0
16.0
04.0

0
1 ot 2 2 ot 3 3 ot 4 4 ot 5
gnitfihs raeG
)elgnis( nusirA )elbuod( nusirA )elpirT( nusirA 82aoR nakyaP
nakyaP pukciP
op noitcirf cificepS

---------------------------------------------------------------------------------------------
 --------------------------------------------------------------------------------------------
61
80.51

41
89.21
78.21

21
62.11
51.11

50.11

01
45.9

32.9
10.9
12.8

8
81.7

48.6

6
02.6

51.6
28.5
86.5
85.5
43.5

55.4

33.4

4
18.3

37.3
72.3
22.3
69.2

18.2
14.2

2
)2mm/N( erusserp ecafruS

75.1

0
1 ot N 2 ot 1 3 ot 2 4 ot 3 5 ot 4

gnitfihs
)elgnis( nusirA raeG
)elbuod( nusirA )elpirT( nusirA
82aoR nakyaP nakyaP pukciP

---------------------------------------------------------------------------------------------
 03

52
64.42

85.02
02
84.51

51

42.21
01.21
53.11

01
60.01

52.8
47.7

29.6
17.6
5

51.5
30.5

88.4

52.3
51.3
90.3
10.2

05.1
83.1
)2mm/N( erusserp ecafruS

88.0
75.0
0
1 ot 2 2 ot 3 3 ot 4 4 ot 5
gnitfihs raeG
)elgnis( nusirA )elbuod( nusirA )elpirT( nusirA 82aoR nakyaP
nakyaP pukciP
2- Gearbox bearings evalution

Input shaft Output shaft

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-------------------------------------------------------------------------------------------------------------------------------------

2-1 Shaft force

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31
Tin = 140* = 241.1 N.m
18

Wt4 * ( 0.088365
2 )= 241.1 Wt4 =5454.6 N

Using approximate values for helix angles and normal and tangential pressure angles, the
component of radial and axial forces can be calculated as follows.

Wr4 = Wt4 * tan φt = 2450 N

Wa4 = Wt4 * tan ψ = 3948 N
-------------------------------------------------------------------------------------------------------------------------------------

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( 0.088365
0.039536 )
r4
Wt1 = Wt4 * Wt1 = 5454.6 * =12191.3N
r1
With the geometric angles of the gears, the values of radial and axial forces of gear 1 can be
calculated in the following way:
Wr1 = Wt1 * tan φ t = 5065.7
Wa1 = Wt1 * tanψ = 6711.5
By writing the force balance equations along the x,y,z direction and the moment balance
equations around the y,z axis, the values of the support forces A, B are obtained.

∑ M Ay=0 →
W rBz =−10370 N

∑ F z=0 → W rAz=3633 N
-------------------------------------------------------------------------------------------------------------------------------------

∑ M Az=0 →
W rBy =−4338 N

∑ F y =0 → W rAy=3177 N
WaB = Wa1 – Wa4 = 6300 -2840 = 2763 N
W rA =√ W rAy +W rAz = √ 3177 2+3633 2=4826 N

W rB =√ W rBy +W rBz =√ 10370 2+ 4338=11240 N

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-------------------------------------------------------------------------------------------------------------------------------------