automotivetransmissionmechanism-140904070720-phpapp01.ppt

1. CHAPTER NO. – 1

2. 1. LOCATION OF CLUTCH
2. FUNCTIONS OF CLUTCH
3. TYPES OF CLUTCH
4. PARTS OF CLUTCH
5. CLUTCH PLATE LINING AND MATERIAL
6. CLUTCH ADJUSTMENT
CLUTCH

3. Clutch is fitted between engine flywheel and
Clutch/Bell Housing.
LOCATION OF CLUTCH
1. Engine
2. Clutch
3. Clutch Paddle
4. Transmission

4. 2. FUNCTIONS OF CLUTCH :
 To Engage Gear or Disengages gears hence
no Gear Crashing sound occurs.
To Balance vehicle on wheels. While initial
starting the vehicle.
To stop Engine from Stalling (stopping)
while Braking.
To let or not to let power transmit from
Engine to gear Box.

5. TYPES OF CLUTCH :
Friction Clutch
 Single Plate Clutch

6. TYPES OF CLUTCH :
Friction Clutch
 Multi Plate Clutch
1) Wet 2) Dry
 Cone clutch Gear free to recive on
shaft
Cone clutch sliding
on
splines in shaft
This face has a lining
of some sort

7. TYPES OF CLUTCH :
 Centrifugal Clutch

8. TYPES OF CLUTCH :
Diaphragm Clutch
 Hydraulic Clutch
1. Pressure Plate
2. Pressure Plate Cover
3. Pressure Spring
4. Clutch Plate
5. Clutch Lining

9.  Single Plate Clutch
o Common type of clutch used in Motor vehicles.
o Consist of only one clutch plate mounted on the
splines of clutch shaft.
o Pressure plate bolted to flywheel through clutch
springs.
o Clutch plate is gripped between flywheel and
pressure plate.
o Clutch shaft is connected to the transmission.
Release Lever Fork
Clutch Plate
Release Bearing
Pressure Plate Assembly
Flywheel
Pilot Bearing

10.  Angage of Single Plate Clutch:
• Clutch remains Engage due to the spring forces.
 Disangage of Single Plate Clutch:
• When the clutch pedal is pressed, the pressure
plate moves back against the force of the springs,
and the clutch plate becomes free between the
flywheel and the pressure plate.

11. Multiplate Clutch
Wet Type Dry Type
 Multi Plate Clutch
• When the clutch is operation in an oil both it is
called wet clutch.
• When the clutch is operated dry it is called dry clu
Multi plate clutch works in the same way as the
single plate.

12. • Pressed by strong coil springs
and assembled in a drum .
• Works in the same way as the
single plate clutch, by operating
the clutch pedal.
• Used in heavy commercial vehicles,
racing cars and motor cycles.
Multiplate Wet Clutch

13.  Cone Clutch
• Consist of friction surfaces in the from of cones.
• Engine shaft consists of female cones.
• Male cone is mounted on the splined clutch shaft.
• When the clutch pedal is pressed, the male cone
slides against the spring force and the clutch is
disengaged.
•Heavy in weight hence not used in modern Automobiles
Gear free to
recive on shaft
Cone clutch sliding on
splines in shaft
This face has a
lining of some sort

14.  Centrifugal Clutch
• Uses centrifugal force instead
of springs force.
• No clutch pedal is required for
operating the clutch.
• Clutch is operated automatically
depending upon the Engine
speed.
• Vehicle can be stopped without stalling the Engine.
• Used in Mopeds.

15.  Diaphragm Clutch:
 The spring is either tapered
finger type or crown type
and is mounted on the
pressure plate.
 Clutch plate remains gripped
between the flywheel
and the pressure plate.
1. Pressure Plate
2. Pressure Plate Cover
3. Pressure Spring
4. Clutch Plate
5. Clutch Lining

16.  Diaphragm Clutch:
 It needs no release levers the
spring itself acts as a series of
levers.
 Driver does not have to exert
heavy pedal pressure to disengage
clutch.
 Mostly used in all modern Automobiles.
1. Pressure Plate
2. Pressure Plate Cover
3. Pressure Spring
4. Clutch Plate
5. Clutch Lining

17.  Hydraulic Clutch
• Used for assistance in single plate clutch.
• Operated by oil pressure instead of
mechanical linkages.
• Consists of clutch master cylinder, fluid line
and slave cylinder.
• Easy to operate.
• Used in modern automobiles.

18.  Clutch plate assembly
 Pressure plate assembly
 Release bearing
 Clutch Pedal Mechanism
4. PARTS OF CLUTCH:

19.  Clutch disk- steel
 Clutch lining – Asbestos and copper wire grit.
 Rivets – Aluminum – copper.
 Torson spring – steel.
 Hub – steel.
5. CLUTCH PLATE LINING AND MATERIAL

20. 6. CLUTCH ADJUSTMENT
A. Floor board clearance adjustment – To prevent from
resting against floor board when the clutch is engaged.
B. Clutch pedal travel adjustment – To ensure complete
clutch disengagement when the clutch is thrown out.
C. Free - adjustment play - To keep a specified amount
of free play in the pedal after the clutch has been
engaged. Normally 1" to 1.5" free play is adjusted.

21. D. Clutch release lever adjustment :
* Done only after removing the clutch from the vehicle.
* The adjustment should be made every time the clutch
is removed.
* Make it as per company's specification.

22. CHAPTER NO. – 2
GEAR BOX

23. INTRODUCTION :-
Next to the clutch is the transmission system
of a motor vehicle.
The word " Transmission" is used for a device
that is located between the clutch and the
propeller shaft.
It may be a Gear Box, a Torque converter, Over
drive, fluid drive or hydraulic drive.
GEAR BOX

24. PURPOSE OF TRANSMISSION :-
To provide high torque at the time of starting,
hill climbing, accelerating and pulling a load.
Obtained by the set of ears called a transmission
or gear set.
Gear set is enclosed in a metal box called a
gear box.
 Vehicle speed can be changed with the help of
Gear Box keeping the engine speed same with
certain limit.

25. TYPES OF TRANSMISSION :-
The transmission are classified as follows :
1.Manually operated selective transmission –
Which are of three types;
1) Constant mesh 2) Sliding mesh 3) Synchro mesh
2. Over Drive :
A semi automatic type used in conjunction with
manual transmission.
3. Automatic transmission – Different ratio between
the Engine crankshaft and the wheels are achieved
by automatic means

26. a)Constant Mesh Gear Box :
* Gear remains in contact constantly with
corresponding Gear of counter shaft .
* Engagement is made by cone clutch .
* Gear are fitted on main shaft.

27. * Because all the Gears are constant mesh , they are
safe from being damaged.
* Unpleasant grinding sound does not occur while
engaging and disengaging them.
* Used in scooters and motor cycles.
* Unpleasant grinding sound does not occur while
engaging and disengaging them.
* Used in scooters and motor cycles.

28. All the Gears and shifts are fitted in a gear housing.
Consist of four shafts :
• Clutch shaft
• Counter shaft
• Main shaft
• Reverse shaft
b. Sliding Mesh Gear Box

29.  Clutch shaft is connected to the drive gear of counter
shaft always.
 Three other gears are rigidly fixed to counter shaft.
 Two or more gear are mounted on the Splined Main
shaft.
 Gear can be slided by shifter Yoke when the shaft
lever is operated.
 Reverse idler gear is mounted on the Reverse shaft
for Reverse motion.
 Used in cars, buses and trucks of old models.

30.  In Modern cars, Helical Gears and synchromesh
devices as used in Gear Box .
 Eliminates clashing of gears and make shifting easier.
 Seemlier to the Constant Mesh Gear Box but provided
with a synchro mesh devised.
Two Gears to be engaged are first brought into
frictional context which equalizes their speed.
 Engagement is done without noise or damaged to
the dogs.
C. Synchro Mesh Gear Box

31. * The clutch shaft gear is connected to the counter
shaft gear.
* Others gears are free hence the transmission main
shaft is not turning.
* Need :
To stop the vehicle after braking without strolling
the Engine.
* To bring the vehicle in motion from neutral the
vehicle is stationary.
NEUTRAL

32. * FIRST GEAR
# Shifted by operating the gear shift lever
# Larger gear of Main Shaft mesh with the
first Gear of counter shaft.
# Gear Reduction of approximately 3:1 is obtained.
First
Speed
Gear
Shifting
Lever
From
Engine
To Rear
Axel

33. # Operated by gear shift lever.
# Larger gear of main shaft is
demeshed from the first gear.
# Gear Reduction of approximately
2:1 is obtained .
SECOND GEAR
Gear
Shifting
Lever
Second
Speed
Main
Shaft
Lay
Shaft
From
Engine
To Rear
Axel

34. To Rear
Axel
# By operating the Gear shift lever
the second gear demishes.
# The second or top gear of the
main shaft is forced axially
against the clutch shaft gear .
* THIRD OR HIGH SPEED GEAR
High
Speed
From
Engine

35. # The main shaft turns with the clutch shaft.
# Gear Ratio of 1:1 is obtained.
* THIRD OR HIGH SPEED GEAR

36. # By gear shift lever, the larger lever of the main shaft
is meshed with reverse idler gear.
# Hence the main shaft turns in the direction opposite
to that of clutch shaft .
# Reverse Rotation of wheels makes the vehicle back.
* REVERSE GEAR

37. CHAPTER NO. 3
PROPELER SHAFT & UNIVERSAL JOINT

38. PROPER SHAFT AND UNIVERSAL JOINT
INTRODUCTION:
# Next to gear box in transmission system
# Connected between Gear Box and differential
# Universal joint at each end.
# Torque is transmitted to rear Axle to which the
rear wheels are connected.

39. PROPELLER SHAFT:
# Transmits the drive from the output shaft of
Gear Box to the Real Axle.
# It must be strong enough to stand up to all the strains.
# It must be light in weight.
# Carefully balanced otherwise at high speeds a
distressing vibration or thrashing will be set up.
# Generally constructed in tubular form.
# Propeller will have to transmit power between two points
at varying vertical and horizontal distances from
each other .

40. * TYPES OF PROPELLER SHAFT:
* TYPES OF PROPELLER SHAFT:
TYPES OF PROPELLER SHAFT:
1. Solid:-
# Heavy in weight.
# Bond to be twisted by force.
# Mostly not used in modern Automobile.
2. Hollow:-
# With stand the torsional stresses of transmitting
torque.
# Light in weight.
# Well balanced so that vibration do not occur
at high speeds.
# Made from strong steel tube.

41. Shaft is in two section – Supper by a centre bearing.
 Propeller Shaft is coupled together by Universal joint.
APPLICATION OF PROPELLER SHAFT:

42. One or more Universal joints are used to permit
variations in angle of drive.
 It is also provided with a sliding joint
to compensate the length.
APPLICATION OF PROPELLER SHAFT:

43. UNIVERSAL JOINT:
# Angular (vertical) movements
provided for by the
provision of universal joints.
# Acts as a universal hinge.
# Slight alternation in length is
accommodated by one and
of the shaft being free to slide on splines.

44. USES:
# Used where two shaft are connected at an angle to
transmit torque.
# Transmission main shaft, propeller shaft and
differential pinion are not in one line hence connected
by universal joint.
# One universal joints connects main shaft and
propeller shaft.
# Other universal joint connects propeller shaft and
differential pinion shaft.
# Universal joint permits the torque transmission
not only at angle but also while this angle is changing
constantly.

45. * DESIGN:
# Simple Universal joint consists of two shaped yokes.
# A cross piece called a spider.
# Four arms of spider known as trunnions.
# Trunnions assembled into bearing in the ends of
two shaft yokes.
# The bearing in the yokes permits the yokes to swing
around on the grunions with each revolution.
# lubrication is provided to lubricates the bearing and
sliding end which should receive regular attention.

46. TYPES OF UNIVERSAL JOINTS
1. Cross type or spider or two yoke type.
2. Ball and trunninon type.
3. Constant Velocity type
1. CROSS TYPE:
* Because it consists of a cross piece or spider it is known
as cross type.
* There are four needle bearings one for each trunnion
the spider.

47. 2. BALLAND TINNION TYPE:
Consists of a ball head fastened to the end of the
propeller shaft. Through which a pin is pressed.
Two steel balls fit over the ends of the pin.
3. CONSTANT VELOCITY TYPE:
Consists of two individual universal joints linked
by a ball and socket.
These type of joint permits uniform motion.

48. CHAPTER NO. 4
REAR AXLE & FINAL DRIVE

49. REAR AXELAND FINAL DRIVE
* REQUIREMENT:
# It is one of cross bars supporting a vehicle on which
the driving wheels turns.
# The Axle increases the torque delivered by the
transmission and transmits it to the driving wheels
via the differential.
# The Axle drive transmits torque at right angle to the
drive shaft.
# Differential can allow one driving wheel to turn faster
than the other during turning.
# The assembly consists of a housing an Axle drive a
differential, two Axle shaft and final drive

50. TYPES OF REAR AXLES:
Depending upon the method of supporting the rear
Axles and mounting the rear wheels the Rear Axles
are of three types:
1. Semi-FLOATING Axles
2. Three Quarter footing Axles
3. Full FLOATING Axles.

51. 1. SEMI FLOATING AXLE:
 Semi Floating axle has a
bearing located on the axle
and inside the axle casing.
 It has to support all the load
of the vehicle.
 It has to be of larger size for
the same torque output than
any other type.

52. 1. SEMI FLOATING AXLE:
The hub of the wheel is
keyed to the outer end
of the Axle.
Semi Floating Axle is the
simples and cheapest of
all other types.
Widely used on cars.
Hub
Axle Shaft
Bearing
Housing

53. 2. THREE QUARTER FLOATING AXLE:
Three Quarter floating axle has bearing located
between the hub and the axle casing.
The weight of the vehicle is transferred to the axle
casing.
Bearing

54. 2. THREE QUARTER FLOATING AXLE:
keyed rigidly to the hub.
It is more reliable.
Not simple use semi floating axle as to remove the
axle the vehicle needs to be jacked up.
Bearing

55. 3. FULL FLOATING AXLE:
Full Floating axle has
two deep-groove ball
or topper roller bearing,
located between the axle
casing and wheel hub.
The outer of the axle
is made flanged to which
the wheel hub is bolted.
The weight of the vehicle
on end thrust.

56. 3. FULL FLOATING AXLE:
 The axle is relieved of all
strain caused by the weight
of the vehicle on end thrust.
The axle may be removed
from the housing without
disturbing the wheel by
removing the nuts.
This type of axle are more
expensive and heavier.
It is usually fitted on commercial
vehicles and buses.
Bearing

57. FINAL DRIVE
Final drive is embodied in the rear axle.
One form of final drive commonly used
in motor vehicle is the chain drive.
Other form of the final drive commonly
used in four wheeled vehicles is the
shaft drive.
Final drive help to turn the drive through
90 from propeller shaft to the rear Axles.
It provides a permanents gear reduction

58. TYPES OF REAR AXLE (DRIVE):
Mainly these are two principal types
of design of Rear Axle housing:
1. Banjo Axle: Most popular types of rear axle and used
on most of the popular priced production models.
2. Split Case Axle: Axle case is usually built up in two
separate halves hence for any the opening and removed
of the axle casing is necessitates.

59. CONSTRUCTION OF DEFFERENTIAL:
Sun gears are mounted on the
inner end of each rear axle.
Ring gear (called the crown gear)
is attached to the cage.

60. CONSTRUCTION OF DEFFERENTIAL:
The cage rotates with the
crown gear.
Crown gear is driven by the
bevel pinion.
Thus when the differential
cage is rotated both the
sun gears rotate and thus
both the wheels turns.

61. When the vehicle is running in a straight line,
the crown wheel, differential cage, planet pinion and
the sun gear all turns as a unit without any relative
motion.
When the car takes a turn, the planet pinions
rotates on their shaft to permit the outer rear
wheel to turn more rapidly than the inner wheel.

62. CHAPTER NO. – 5
FRONT AXLE

63. FRONT AXLE
INTRODUCTION :
• Front axle is used to carry the weight of the
front part of the vehicle .
• It facilitates the stearing mechanism.
• It absorb shocks due to the road surface
variations.
• It must be right and robust in construction.
• It is made of "I" section in the centre
portion , while the ends are made either
circular or elliptical.
• Different components of the front axle
are the axle beam , stab axle , king pin , tie rod.

64. Types of Front Axles
Usually there are two main types of front axles
1) Live axle 2) Dead front axle
1) - Front axles are usually dead axles because
they do not rotate

65. Types of Front Axles
- A live front axle receives additional power
from the gear box transfer case
- Live axle receives the power of the engine
2) Dead axle do not receive the power
of engine but moves with the help
of the driving force of rear axles .
The wheels are mounted on the stub
axles which are often pivoted.

66. STUB AXLE
- The stub axle turns on the king pin
which is a light drive fit in the axle
beam eye located and locked by a taper
cotter pin.

67. STUB AXLE
-Bronze buses are fitted in to the forked
ends of the axle to the axle to provide
a bearing surface for the king pin.
- Vertical load are taken by thrust bearing`
located either on the top fork of the stub
axle are between the lower fork and the
underside of the beam.

68. There are four types of stub axles
1. Elliot
2. Reverse Elliot
3. Lamoine
4. Reverse Lamoine
Types of Stub Axles

69. ELLIOT TYPE
In elliot stub axle is attached to the front axle by
placing it in the yoke end with a king pin and
cotter pin to poin two together
REVERSE ELLIOT
In reverse Elliot type stub axle the arrangement is
reversed. It is widely used in current auto mobiles used
in trucks
LEMOINE
In lemoine type stub axle instead of yoke type hinge
a L- shaped spindle is used as shown in fig used in
tractors
REVERSE LEMOINE
It is the reverse position of lemoine but not used in
modern automobiles.

70. CHAPTER NO. – 6
SUSPENSION SYSTEM

71. SUSPENSION SYSTEM
INTRODUCTION :
#The suspension is a system of devices that effect an elastic
connection between the under carriage and the wheels.
# Its purpose is to absorb any road shocks that results
from the wheels hitting holes or bumps.
# Suspension system includes springs, shock absorbers
and their mountings.
# Suspension system of a vehicle is divided into the rear
and suspension and front suspension.

72. PRINCIPAL OF SUSPENSION SYSTEM :
# These system works on two principals
1. Tensile Strength
2. Compression Strength
1. To prevent the road shocks from transmitted to the
vehicle frame.
2. To preserve the stability of the vehicle in pitching or
rolling, while in motion.
3. To safeguard the occupants from road shocks.
4. To provide good road holding while driving, cornering
and breaking.
5. To maintain proper steering geometry.
FUNCTION OF SUSPENSION SYSTEM

73. REQUIREMENTS OF SUSPENSION SYSTEM
1. Minimum deflection consistent with required stability.
2. Comparability with other vehicle components- types
frame, wheel base, steering linkage.
3. Low maintenance and operating costs.
4. Low initial cost.
5. Minimum weight.
6. Minimum Tyre wear

74. # The front suspension is more complicated than the
rear end suspension.
# The front wheel not only moves up and down but
also swing at various angles during stearing
FRONT END SUSPENSION & TYPES :
# The front end suspension may be of Two types
1) Rigid suspension 2) Independent suspension.

75. INDEPENDENT SUSPENSION :
# Each front wheel is independently
supported by a coil spring, torsion bar.
# This type of suspension is able to cushion
road shochs by causing the lower arm to
twist the torson bar.
# A shock absorber is the supportive member
for the independent suspension.
# Almost all the passenger cars now use the
independent suspension.

76. * Provides mere space for engine accommodation.
* Provides softer suspension.
* Effect on the stearing geometry is over come with
Independent front suspension.
* Weight is low.
* Reduces the tendency of causing wheel wobble
or shimmy.
*Reduces the tendency of tilting the vehicle to one side
when the wheel is lifted or drop due to road variations.
ADVANTAGES OF INDEPENDENT SUSPENSION :

77. # Fig shows a typical rigid axle wheel suspension.
# Universally used before the introduction of
Independent suspension.
# Two longitudinal leaf spring or transverse spring in
conjunction with shock absorber is used.
RIGID AXLE SUSPENSION :

78. TYPES OF INDEPENDENT SUSPENSION SYSTEM :
1. Vertical Slide Method
2. Divided Axle Method
3. Swing arm Method
4. Parallel link Method
Shock Absorber
Coil Spring
Stabilizer
Ball Joints
Upper Control Arm

79. TYPES OF INDEPENDENT SUSPENSION SYSTEM :
TYPES OF SUSPENSION SPRING :
1. Leaf spring
2. Coil spring
3. Torsion spring
4. Air Bags
5. Rubber spring
Rear Shakle
Shock Absorber
Leaf Spring
Front Hanger

80. LEAF SPRING :
Leaf springs are of the following types
1) Semi-elliptical spring
2) Quarter elliptical spring
3) Three quarter elliptical spring
4) Transverse spring
5) Full elliptical spring
6) Platform type spring
# Semi-elliptical spring are usually used in all the vehicles.
Quarter Elliptical
Semi Elliptical
Three Quarter
Elliptical
Transverse Spring
Axle

81. PARTS OF RIGID AXLE SUSPENSION :
1. Main Leaf
2. Helper Leaf
3. Shackle
4. Bracket
5. Centre bolt
6. 'C' clamp
7. 'U' bolt
8. Shackle pin
Helper Spring
Rubber
Bush Frame Bracket
Spring
Bollt
Rubber
Bush
Shackle Lings
Shackle pin
Rubber Packing
Metal Plate
Lower Clamp plate
Mrtal
Housing
Rollers
Rubber
Bumper
Rubber Packing

82. PARTS OF INDIPENDENT SUSPENSION
1. Upper Arm
2. Lower Arm
3. Ball Joints
4. Coil Spring
5. Shock Absorber
6. Torson bar/ Stabilizer bar