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Design and Fabrication of GearBox             Department of Mechanical and Automobile Engineering,26/11/2009              ...
AIM: To design and fabricate a                 automobile gearbox    Objectives    •To design a Helical gear box    •Study...
Representation of Gearbox  Motor               Gear box                                Gear                 Department of ...
Market Survey   Market research was done at following places   regarding type and cost calculation of the   Gearbox.   •So...
Gearbox  A transmission or gearbox provides speed and tor  que conversions from a rotating power source to  another device...
Uses of Gearbox   •Gearbox has different uses at different places.   •In Automobiles, engine speed is about 5000   rpm ,bu...
Gearbox typesIt can be classified as•Manual•AutomaticManual Gearbox can be further divided as5.Synchromesh and Non Synchro...
Synchromesh GearBox  Constant Mesh Gearbox where diagonal cut  helical gear sets are constantly "meshed"  together, and a ...
Material Selection    • Keeping in mind cost effectiveness. It was      intended to design a general purpose      Gearbox,...
Materials contd.    • Plain Carbon Steel with 0.4% carbon or EN8      material is selcted for shaft.    • Further,Hot roll...
Automatic Gearbox    • This type of transmission are easy to use.       Automatic transmission will select an      appropr...
Design of Automobile Gearbox    • Gearbox are incorporated to match performance      of variable speed internal combustion...
Special features of Automobile Gear                       box    • Universally accepted number of gear ratios is      4.Th...
Results Obtained             Department of Mechanical and Automobile Engineering,26/11/2009                   Institute of...
Gear Ratios             1st gear ratio                                                 4:1             2nd gear ratio     ...
Layout             Department of Mechanical and Automobile Engineering,26/11/2009                   Institute of Technolog...
Results    Pitch line velocities for different gear pairs              Gear Pair                                     Veloc...
Gantt Chart                         Task                               Start Date   End Date Days Completed Days Remaining...
Conclusion  Designing of gears and shafts has been done and near  future we will be starting with fabrication of gearbox. ...
Acknowledgement             Department of Mechanical and Automobile Engineering,26/11/2009                   Institute of ...
Bibliography  •P.S.G Design Data book  •Handbook for engineers  •Material Science By Rk Rajput  •Mechanical System Design ...
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Transcript of "Design and fabrication_of_gear_box"

  1. 1. Design and Fabrication of GearBox Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
  2. 2. AIM: To design and fabricate a automobile gearbox Objectives •To design a Helical gear box •Study of various gear manufacturing processes •Fabrication of gear box Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
  3. 3. Representation of Gearbox Motor Gear box Gear Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
  4. 4. Market Survey Market research was done at following places regarding type and cost calculation of the Gearbox. •Sokhi heli-wom gears pvt.ltd in Ghaziabad •Hi-tech gears in Manesar •Junk market in Mayapuri Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
  5. 5. Gearbox A transmission or gearbox provides speed and tor que conversions from a rotating power source to another device using gear ratios, including for a motor vehicle partly because of the limitations of internal combustion engines. Torque converters, hydraulics, electrical power and hybrid configurations may also be used for the same purpose. Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
  6. 6. Uses of Gearbox •Gearbox has different uses at different places. •In Automobiles, engine speed is about 5000 rpm ,but wheels rotate at 1000 rpm.Machine tool spindle rotates at 50 rpm while the motor is at 1440 rpm. •Automobile gearbox can have variable output and input speeds ,and few reduction ratios in between. Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
  7. 7. Gearbox typesIt can be classified as•Manual•AutomaticManual Gearbox can be further divided as5.Synchromesh and Non SynchromeshNon synchromesh includes :sliding mesh type Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
  8. 8. Synchromesh GearBox Constant Mesh Gearbox where diagonal cut helical gear sets are constantly "meshed" together, and a dog clutch is used for changing gears. On synchromesh boxes, friction cones or "synchro-rings" are used in addition to the dog clutch. This type of gearbox is used in modern cars and trucks these days. Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
  9. 9. Material Selection • Keeping in mind cost effectiveness. It was intended to design a general purpose Gearbox, where cheaper materials would be used. • So, Plain Carbon Steel will be used for moving components and Cast iron for Frames and bodies ,because of intricate shape they can be easily casted. Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
  10. 10. Materials contd. • Plain Carbon Steel with 0.4% carbon or EN8 material is selcted for shaft. • Further,Hot rolled being cheaper than cold rolled and heat treated materials , hot rolled will be selcted. • For gears : 30 Ni 4 Cr 1 is selected with Sut=1500Mpa • For gears, additonal cheap alloying element,such as manganese (0.87%),to make it Strong , giving ultimate strength of 600 Mpa.(P.S.G Design data book 1.13) Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
  11. 11. Automatic Gearbox • This type of transmission are easy to use. Automatic transmission will select an appropriate gear ratio without any operator intervention . • Sun and planet gear are mainly used Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
  12. 12. Design of Automobile Gearbox • Gearbox are incorporated to match performance of variable speed internal combustion engine. • Lowest reduction ratio is needed at highest speed of operation, and vice versa, values of these reduction ratio lies b/w 3.5 to 4.5 for cars and 5 to 7 for commercial vehicles.Gearbox provides reduction ratio between 1:1 to 1:4 for cars to 1:1 to 1:7 for commercial vehicles. Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
  13. 13. Special features of Automobile Gear box • Universally accepted number of gear ratios is 4.These four are in geometric progression, However ,overdrive gear is provided to enhance performance at higher speeds • Additional reduction ratio is provided to enhance performance during higher gradient operation. Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
  14. 14. Results Obtained Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
  15. 15. Gear Ratios 1st gear ratio 4:1 2nd gear ratio 2.52:1 3rd gear ratio 1.58:1 4th gear ratio 1:1 5th gear ratio 1.58:1 6th gear ratio 2.52:1 7th gear ratio 4:1 Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
  16. 16. Layout Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
  17. 17. Results Pitch line velocities for different gear pairs Gear Pair Velocity(km/hr) GH 33.9 AB 67.9 CD 57 EF 44.7 Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
  18. 18. Gantt Chart Task Start Date End Date Days Completed Days Remaining 1. Problem Formulation 09/01/09 09/30/09 21 0 2.Literature and market survey 10/01/09 10/31/09 31 0 3.Design of gears and shafts 11/01/09 11/30/09 25 5 4. Cutting of gears 01/20/10 02/28/10 0 38 5. Gear assembling and casing 03/01/10 03/31/10 0 31 6. Final Report 04/01/10 04/30/10 0 30 Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
  19. 19. Conclusion Designing of gears and shafts has been done and near future we will be starting with fabrication of gearbox. Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
  20. 20. Acknowledgement Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
  21. 21. Bibliography •P.S.G Design Data book •Handbook for engineers •Material Science By Rk Rajput •Mechanical System Design By S.P . Patil •Theory of machine By Khurmi & Gupta •Machine Design By Khurmi & Gupta Department of Mechanical and Automobile Engineering,26/11/2009 Institute of Technology and Management, Gurgaon
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