You are on page 1of 34

# CHAPTER-3

## DESIGN OF GEAR BOX/TRANSMISION

August,2018 1
Introduction
• Functions of Transmission
– To provide a means to vary the torque ratio by set of gears
between the engine and the road wheels as required. That is to
provide the high torque at the time of starting, hill climbing,
accelerating and pulling a load since high tractive effort is
needed
– It permits engine crankshaft to rotate at high speed, while the
wheels turn at slower speeds and Vehicle speed can be changed
keeping engine speed same with certain limit
– To provide a neutral position so that the engine and road wheel
are disconnected even with the clutch is in engaged position
– To provide a means of reverse the car by reversing the direction
August,2018 2
of rotation of the drive.
Necessity of Transmission
• To vary the torque to overcome the various resistance acting
against the vehicle motion at various speeds
• To vary the tractive effort of the vehicle available at various
speeds in order to overcome the various resistance
• to start the vehicle from rest, with the engine running
continuously
• To Stop the vehicle by disconnecting the drive when appropriate
• Total resistance consists of
– Wind resistance
– Rolling Resistance
August,2018 3
Necessity of Transmission
IV- level

1 Gear

III- level
Tractive Effort and Total Resistance

2nd Gear

II- level
I- level

3rd Gear

o A B C
Speed
August,2018 4
Necessity of Transmission
• Let the vehicle is traveling on a top gear and the total resistance is
taken curve-I
– OB is the stabilizing speed
– The speed below OB (OA) give acceleration
– The speed beyond OB (OC) gives deceleration
• If the vehicle negotiate the curve-III obstacle
• The top gear curve does not cross curve-III, i.e the vehicle can not
go at this gear to overcome the give resistance
• If the gear shifted to the 2nd gear
– OA is the stabilizing speed
• Similarly with the 2nd gear not possible to negotiate the curve-IV
resistance, for which the 1 st gear has to be selected
August,2018 5
Gearbox Designs
Calculation of Gear Ratios
The speed and traction equations can be used to calculate the gear
ratios of a gearbox as well as vehicle performance.
Theoretically the engine should work at its maximum power to
have the best performance.
All automotive transmissions are equipped with:
 a varied number of forward speed gears,
 a neutral gear, and
 one reverse speed.

August,2018 6
Overdrive: reduces engine speed at a given vehicle speed, which
increases top speed, improves fuel economy, and lowers engine
noise.

August,2018 7
August,2018 8
August,2018 9
Selecting the gear ratios for the intermediate gears
• To determine the middle gear ratios, there are two
recommended methods:
1. Geometric ratios
2. Progressive ratios
• The method for selecting the gear ratios for the intermediate
gears between the highest and the lowest is, to a great extent,
dependent upon the type of vehicle.
• For heavy commercial vehicles, the gear ratios are usually
arranged in a geometric ratio.
– The basis for this is to have the engine operating within the
same speed range in each gear.
– This would ensure that in each gear, the operating fuel
economy is similar.
• For instance, for a four-speed gearbox, the following
relationship can be established:

August,2018 10
• If the ratio of the highest gear ξn, and that of the lowest
gear ξ1, have been determined, and the number of speeds
in the gearbox ng, is known, the factor Kg can be
determined by:

## Selection of gear ratio based on geometric progression rule.

August,2018 11
Exercise
1. Consider the working range for the engine is between 2600 rpm and
5000 rpm. The diﬀerential of the vehicle uses nd = 4, and the
eﬀective tire radius is rw = 0.326 m. We like to design a three-gear
geometric gearbox having overall efficiency of 84%. We assume
that the total resistance force is constant, and the engine cannot
accelerate the car at Vx = 180 km/hr anymore.
2. Calculate the gearbox and final drive ratios for a vehicle from the
given data. Maximum engine torque is 105.2 Nm at 2100 rpm.
Maximum power is 37.3 kW at 4000 rpm, giving a maximum road
speed of 130 km/h. The rolling radius of road wheels is 0.366 m.
Transmission efficiency is 90% and the maximum tractive
resistance is 4890 N.

August,2018 12
Exercise
3. Sketch a section through which a constant mesh gear box with four
speed and explain how the different gear ratios will be obtained in
the following cases.
– Gear ratios on top gear 1:1
– Gear ratios on 3rd gear 1.38:1
– Gear ratios on 2nd gear 2.24:1
– Gear ratios on 1st gear 3.8:1
• Assume countershaft speed is half that of the engine speed and
smallest gear is not to have less than 15 teeth.

August,2018 13
GEAR TRAINS
 A gear train is two or more gear working together by meshing their teeth and
turning each other in a system to generate power and speed.
 It reduces or increases speed and torque
 Types of gear train:
a) Simple gear train
b) Compound gear train
c) Planetary gear train
d) Riveted Gear train
 For any gear, the pitch diameter is
proportional to the number of teeth (T)
 The speeds of the gears are inversely
related to the diameter.
 Torque is proportional to pitch diameter
𝑇𝑂𝑢𝑡 𝐷𝑂𝑢𝑡 𝑁𝑂𝑢𝑡 𝝎𝐼𝑛 Number of Out put Gear teeth
𝑇𝐼𝑛
= -
𝐷𝐼𝑛
=-
𝑁𝐼𝑛
=-
𝝎𝑂𝑢𝑡
GearRatio 
Number of input Gear teeth

August,2018 14
1. Simple Gear Train

 The most common of the gear train is the gear pair connecting parallel
shafts. The teeth of this type can be spur or helical .

 Only one gear may rotate about a single axis Input shaft
Driven gear = 10
teeth

## Gear ratio = 2:1 Output shaft Driving

August,2018 gear = 20 teeth 15
Simple gear train
• When there is only one gear on each shaft as shown in
figure below it is known as simple gear train.

August,2018 16
2. Compound Gear Train
 For large velocities, compound arrangement is preferred
 Two or more gears may rotate about a single axis
• Multiple simple gear trains in series
• Each set of gears generates an individual ratio
• Multiply individual ratios together to work out overall ratio.

August,2018 17
Compound Gear Ratios

## Compound Gear ratio = *

August,2018 18
Compound gear train

## • When there is more than one gear on a shaft as shown in

figure below it is called a compound train of gear.

𝑁1 𝑇2
=
𝑁2 𝑇1
𝑁3 𝑇4
=
𝑁4 𝑇3
𝑁5 𝑇6
=
𝑁6 𝑇5
August,2018 19
3. Reverted Gear Train

## When the axes of the first driver

and the last driven are co-axial,
then the gear train is known as
reverted gear train.
 In a reverted gear train, the
motion of the first gear and the last
gear is same.
Since the distance between the
centers of the shaft of gears 1 & 2
as well as gears 3 & 4 is same:
r1+r2 = r3+r4

August,2018 20
Reverted gear train

## • Also circular pitch or module of all the

gears is assumed to be same, therefore
number of teeth on each gear is
directly proportional to its

August,2018 21
Example

## • The speed ratio of the reverted gear train as shown in figure

below, is to be 12. the module pitch of gears A & B is 3.125mm
and of gears C & D is 2.5mm. Calculate the suitable numbers of
teeth for the gears.

August,2018 22
4. Epicyclic gear train
 Epi means Upon and
 Cyclic means Around.
• In epicyclic gear train the axis of the shafts over which the gears
are mounted may move relative to a fixed axis.
• The epicyclic gear trains may be simple or compound.
• The epicyclic gear trains are useful for transmitting high velocity
ratios with gears of moderate size in a comparatively lesser space.
• They are used in Lathe, Automatic transmission, differentials and
pulley blocks etc.

August,2018 23
Simple Epicyclic gear train

## • Planetary Gear Set

– Is a serious of interconnecting
gears consisting:
 Sun Gear
 Several Planetary pinion
Gear
 Ring Gear
 Carrier: connecting the pinion
gears to the ring gear

August,2018 24
Simple planetary gear operation
Power Power Rotational
Held Rotational direction
input output Speed Torque
Sun gear Carrier Reduced Increased The same direction
Ring gear
Carrier Sun gear Increased Reduced as drive member
Ring gear Carrier Reduced Increased The same direction
Sun gear
Carrier Ring gear Increased Reduced as drive member
Sun gear Ring gear Reduced Increased Opposite direction as
Carrier
Ring gear Sun gear Increased Reduced drive member

August,2018 25
August,2018 26
Example
• The gearing of machine tool is shown as figure below. The
motor shaft is connected to gear A and rotates at 975
rpm. The gear wheels B,C,D and E are fixed to parallel
shaft. Determine the speed of gear F. the number of teeth
on each gear are shown as table below.

August,2018 27
Examples
1. If number of ring gear teeth is 56 and sun gear is 24,
determine gear ratio when the sun gear is fixed and
ring gear operates as the input member .
2. Based on question number 1, calculate the gear ratio
when carrier is used as input member and the ring
gear is the output member.

August,2018 28
Examples

August,2018 29
August,2018 30
August,2018 31
August,2018 32
4. An Epicyclic gear train has sun and annulus gears with 28
and 56 teeth respectively. If the input speed from the
engine drives the sun shaft at 3000 rev/min, determine
– (a) the number of planet-gear teeth,
– (b) the overall gear ratio, and
– (c) the pinion carrier-shaft output speed.

August,2018 33
Solution
(a) the number of planet-gear teeth
TA=TS+2TP
 TA  TS 
TP   
 2 
 56  28  28
   14 Teeth
 2  2

## (b) the overall gear ratio

N S Z C Z S  2Z P
GR   
NC Z S ZS
 28  56  84
GR     3 :1
 28  28

## (c) the pinion carrier-shaft output speed

NS N S 3000
GR   NC    1000rpm
August,2018
NC GR 3 34