UNIT ONE

1. INTRODUCTION

Gearbox often referred as transmission is a unit that uses gears and gear trains to provide speed
and torque conversions from a rotating power source to another device. Gearboxes are employed
to convert input from a high speed power sources to low speed (E.g. Lift, Cranes and Crushing
Machine) or into a many of speeds (Lathe, Milling Machine and Automobiles). A gear box that
converts a high speed input into a single output it is called a single stage gearbox. It usually has
two gears and shafts.

 A gearbox that converts a high speed input into a number of different speed output it is
called a multi-speed gear box. Multi speed gear box has more than two gears and shafts. A
multi speed gearbox reduces the speed in different stages.

 An automobile requires high torque when climbing hills and when starting, even though
they are performed at low speeds. On other hand, when running at high speeds on level
roads, high torque is not required because of momentum. So requirement of a device is
occur, which can change the vehicle’s torque and its speed according to road condition or
when the driver need. This device is known as transmission box.

1.1. Background on gearbox

The motion and power transmitted by gears is kinetically equivalent to that transmitted by
frictional wheels or discs. As the effect of slipping (reduced velocity ratio) of a belt or rope is
cause to the innovation of gears or toothed wheels (for definite velocity ratio of the distance
between the driver and the driven is very small), the detail knowledge on previous gearbox
(sliding gearbox) leads for advanced gear box (constant mesh) innovations in order to improve
efficiency, wear, noisy and other effects of the gearbox. Those problems are solved by
appropriate material selection and changing gear type used [1].

1.2. General concept on a gearbox

Gearbox is the one mechanical device from transmission system (i.e. Clutch, gear box, Propeller
shaft, Universal joints, differential, Rear axle, Wheel, Tyre) and which provides speed and
torque 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. A gearbox
is formed by mounting different gears in appropriate speed ratios to obtain the desired variations
in speed [3].
Gearboxes work on the principle of meshing of teeth, which result in the transmission of motion
and power from the input source to the output. The main purpose of a gearbox is to transmit
power according to variable needs from an input power source to the desired output member. As
the speed of the shaft increases, the torque transmitted decreases and vice versa. Multi-speed
gearboxes are used in applications which require frequent changes to the speed/torque at the
output shaft. There are many types of gearboxes like constant mesh, synchronous, slide gear box
systems. This design concerns on manual (not automatic) constant mesh gearbox in detail.

1.3. Literature review

Ancient engineers were aware of the desired performance parameters such as a gear ratio, center
distance and available power source (water, wind, horse power and engine power) and used
them to define the gear parameters (diameters, number and shape of the teeth). This implies that
design of gearbox is not new innovation since it is done by much researchers and even last year
students. The only difference is that the magnitudes of the required parameters (dimensions) and
stress analysis since the given specifications are different.

When this gearbox is designed, it is for the following purposes and applications:

The main use of a gearbox is to act as a speed reduction and do the opposite with the
positive drive (without slipping).
To changing the direction through which the power is transmitted.
To changing the amount of force or torque that is transmitted.
To changing the revolutionary speed of the input relative to the output.
Reduce the load on the motor by using the motor's own momentum to keep it turning.
Reduces wear on the engine, allows more control & greater speeds.
Applications
 In different Automobiles
 Industrial, agricultural, construction machines and
 Aircraft's

1.4. Objective of design

1.4.1. General objective

The general objective of this project is to design a backward arrangement of a gearbox for
transmitting 5 kW of power at 1450 revolutions per minute with a speed ratio of 12.5, we need
to calculate the output speed and torque required at the output shaft of the gearbox. Design the
backward arrangement of a gearbox with considerations of appropriate material selection,
strength and dimensional analysis for each components and assemblies so as to achieve desired
torque/speed.

1.4.2. Specific objective

 To design a backward arrangement of a gearbox for transmitting 5 kW of power at 1450
revolutions per minute with a speed ratio of 12.5, we need to calculate the output speed and
torque required at the output shaft of the gearbox.

Given:

 Input Power (Pin) = 5 kW

 Input Speed (Nin) = 1450 RPM
 Speed Ratio (N1/N2) = 12.5
First, we need to calculate the output speed (Nout) and output torque (Tout) at the output shaft
of the gearbox using the following formulas:

Output Speed:

Nout = Nin/Speed Ratio

Nout = 1450/12.5

Nout = 116 RPM

Output Torque:

Pout = Pin

Tout = (Pout * 60) / (2 * π * Nout)

Tout = (5000 * 60) / (2 * π * 116)

Tout ≈ 204.6 Nm

Once we have calculated the output speed and torque, we can proceed with selecting suitable
gears and shafts to design the gearbox in a backward arrangement with a casting housing to
transmit the required power and torque.

 To identify each components of backward arrangement of a gearbox (i.e. Gear, Shaft and
key, Bearing, Housing and Lubrication).
 To design and calculating the required parameters of each components using the following
design specification.

Given:

 Input Power (Pin) = 5 kW

 Input Speed (Nin) = 1450 RPM
 Speed Ratio (N1/N2) = 12.5

1.5. Gear Types that could be used in this Design

A. Spur gear: are gears which have vertical Upright teeth perpendicular to the radial axis of the
Gear wheel.
 Easy to find (available)
 Inexpensive, and
 Efficient but cannot be used when a direction changes
B. Helical gear: have teeth inclined to the axis of rotation

Even if it is:

 Limited cutters are used for manufacturing.

 May be expensive and difficult to be available at everywhere.
But it is:
 Produce less noise than spur gears of equivalent quality because the total contact ratio is
increased.
 As a result of the increased total area of tooth contact available, the load capacity of
helical gears is generally higher than that of equivalent spur gears
 In the design of a gear system, it is often necessary to use a specific ratio on a specific
center distance. Frequently this results in a diametral pitch which is non -standard. If
helical gears are employed, a limited number of standard cutters may be used to cut a
wide variety of transverse-pitch gears simply by varying the helix angle, thus allowing
virtually any center-distance and tooth-number combination to be accommodated.
 Long life of the gears. (So, single-helix gear chosen for this design)
C. Bevel gear: have teeth formed on conical surface and are used mostly for transmitting
motion between intersection shafts.
D. Worm gear: represent the worm resembles a screw. Gearboxes may be manual and
automatic gearbox.
 Manual gearbox Automatic gearbox
1 Vehicles with manual transmission Vehicles with automatic transmission are costlier than those
are usually cheaper. of manual transmission
2 Better fuel consumption. This is It has not better fuel economy. This is because it has not
because manual transmission has better mechanical and gear train efficiency as compare to
better mechanical and gear train those of automatic transmission
efficiency.
3 It offers the driver more control of Automatic transmission does not offer the driver more
the vehicle. control of the vehicle as compare to that of automatic
transmission system.
Since manual transmission has those above listed positive sides, it is preferable for this design.

1.6. Types of gearboxes

i. Sliding Mesh Gear box

ii. Constant Mesh Gear Box
iii. Synchrony Gear Box

1.6.1. Sliding mesh gear box

 In this type of gear box, the main shaft gear wheels slide on splines in the direction of
selection to mesh with the appropriate lay shaft gear for first, second, and third gears.
 Top gear is a dog clutch connection joining input and output shafts to give a 1:1 ratio.
 For reverse the 'compound' idler gear slides along the shaft to mesh with main shaft and
lay shaft first gear wheels.
 To enable all this to happen all the gear teeth are cut straight.
 This type is no longer used in the modern motor vehicle, as the gears are difficult to
change without some noise occurring.
1.6.2. Constant mesh gear box
 In a constant mesh gear box, the main shaft gearwheels rotate on bushes and are in
constant mesh with the lay shaft gears.
 The appropriate gearwheel may then be locked to the output shaft and made to revolve
with it by a dog clutch spline to the shaft and slide along it by the same sort of selector
fork and collar as was used in the sliding mesh gearbox.
This constant mesh gearbox has the following advantages.
 It allows the use of helical gears;
 It is quieter in operation than spur-type teeth;
  It is stronger than the spur type as there is more than one tooth in engagement at any
one time;
 It makes gear changing easier as the gear wheels have to be rotating at the same speed
before engagement can take place (this is achieved through the use of a Synchrony
device) [3].

1.7. Shaft layout in constant mesh gearbox

It is simplest type of gear box out of the available gear boxes. Four speeds Constant Mesh Gear
Box (Which includes one reverse gear) consists of three shafts
a. Input (clutch or driving) shaft:-it has one gear which is rigidly fixed. This input shaft
usually forms a direct link between the engine and gearbox.
b. Main (output or driven) shaft:-it is the spline final shaft in the internal running gear
shafts and has four gears on it; the main shaft can be clamped due to dog clutch by the
shifter yoke by operating the shift lever.
c. Counter (lay) shaft; it used to transmit motion and power from a driving shaft to output
shaft and it has four gears which are rigidly connected.

Figure 1.Shaft layout

1.8. Major components of manual gearbox

Gear Bearing
Shaft Housing and Lubrication
Key Gog clutch

Gears are machine elements, which are used for power transmission between shafts, separated
by small distance. Gears are widely used in applications which require high load carrying
capacity, high efficiency and no slip between the meshing shafts. Irrespective of the type, each
gear is provided with projections called teeth and intermediate depressions called tooth spaces.
While two gears are meshing, the teeth of one gear enter the spaces of the other. Thus, the drive
is positive and when one gear rotates, the other also rotates; transmitting power from one shaft to
the other [6].
Shafts are the members of the gearbox that transmit the rotary motion of the gears to subsequent
stages and also transmit power from one stage to the other. They are also the members on which
the gears are mounted .The shafts are coupled to the bearings to enable the shafts to rotate
without much friction.
Keys are machine elements used to prevent relative rotational movement between a shaft and
the parts mounted on it, such as pulleys, gears, wheels, couplings, etc. [6]
Bearing, applied to a machine or structure, refers to contacting surfaces through which a load is
transmitted. When relative motion occurs between the surfaces, it is usually desirable to
minimize friction and wear. [2]
Lubricant is any interposed substance that reduces friction and wear. Lubricants are usually
liquid but can be a solid, such as graphite, TFE, or molybdenum disulphide, or a gas, such as
pressurized air. [2]

1.9. Working principle

 Gearboxes work on the principle of meshing of teeth, which result in the transmission of
motion and power from the input source to the output by using counter or intermediate
shaft.
 In a constant mesh gear box, the output/main shaft gearwheels rotate on bushes and are
in constant mesh with the lay shaft gears.
 The appropriate gearwheel may then be locked to the output shaft and made to revolve
with it by a dog clutch spline to the shaft and slide along it by the same sort of selector
fork and collar as was used in the sliding mesh gearbox.
Figure2. Working principle
 UNIT II

2. DESIGN OF CONSTANT MESH GEARBOX

The constant mesh gearbox is a classic and widely used type of manual transmission system
found in numerous vehicles. This robust and reliable gearbox design has stood the test of time,
offering efficient and smooth gear shifting for decades. Unlike other transmission systems, all
gears in a constant mesh gearbox remain engaged with their respective shafts. The key to its
seamless operation lies in its ingenious design, which employs sliding gears into place while
rotating, avoiding the need for clutch disengagement during gear changes. This enduring
technology has played a crucial role in enhancing driving experiences, providing drivers with
greater control and ease of operation on the road.

What is Constant Mesh Gearbox?

Fig 1: Constant Mesh Gearbox

The Constant Mesh Gearbox, developed as an improvement over the sliding mesh gearbox,
revolutionized manual transmissions by employing a design where all gears remain constantly
meshed. Unlike its predecessor, the gears in this gearbox are fixed and do not slide. Instead, dog
clutches were introduced as new shifting devices to achieve smooth gear changes.

Typically equipped with a 4-speed 1-reverse manual transmission configuration, the constant
mesh gearbox incorporates parts like the countershaft, main shaft, clutch shaft, gears, and dog
clutches. Employing helical and herringbone gears, it operates with reduced noise compared to
the sliding mesh gearbox that utilizes spur gears. The constant engagement between gears on the
main shaft and countershaft enables different transmission ratios, providing varying speed and
torque outputs by engaging the dog clutches with the desired gears on the main shaft.
Construction of Constant Mesh Gearbox
The main parts of Constant Mesh Gearbox are:
Shafts:
i) Main Shaft:
Also known as the output shaft, it accommodates dog clutches and gears, allowing the gears on
this shaft to rotate freely.
ii) Lay Shaft or Counter Shaft:
Serving as an intermediate shaft between the Main Shaft and Clutch Shaft, the gears on the
countershaft are constantly meshed with the gears on the main shaft and are directly connected
to it.
iii) Clutch Shaft:
Acting as an input for the gearbox, the clutch shaft carries the engine output to the gearbox.
Dog Clutch:
Dog clutches facilitate the coupling of the lay shaft and main shaft through interference rather
than friction, enabling the transmission of appropriate gear ratios to the main shaft.
Gears:
Gears in the constant mesh gearbox are paired between the lay shaft or countershaft and the
main shaft, providing different gear ratios. The gears used in this gearbox are of two types:
i) Helical Gears:
Angular cut teeth over a cylindrical cross-section metal body.
ii) Bevel Gears:
Angular cut teeth over a conical cross-section metal body.
Constant Mesh Gearbox Working

Fig 2: Constant Mesh Gearbox diagram

In the constant mesh gearbox, the gears are continuously meshed, allowing the use of two dog
clutches to achieve four different gears. In the neutral position, the dog clutches do not engage
with any gear, enabling free rotation of the output shaft gears. The gear selections and power
transmission paths for each gear are as follows:
First Gear:

Fig 3: First Gear

When dog clutch 1 moves towards the left, it meshes with gear A, causing the output shaft to
rotate.
Power transmission path: Engine shaft -> Clutch gear -> Gear 5 -> Lay shaft -> Gear 4 ->
Gear A -> Output shaft.
Second Gear:

Fig 4: Second Gear

When dog clutch 1 moves towards the right, it meshes with gear B, resulting in the rotation of
the output shaft.
Power transmission path: Engine shaft -> Clutch gear -> Gear 5 -> Lay shaft -> Gear 3 ->
Gear B -> Output shaft.
Third Gear:
 Fig 5: Third Gear

When dog clutch 2 moves towards the left, it meshes with gear C, causing the output shaft to
rotate.

Power transmission path: Engine shaft -> Clutch gear -> Gear 5 -> Lay shaft -> Gear 2 ->
Gear C -> Output shaft.

Fourth Gear:

Fig 6: Fourth Gear

Fourth gear provides the highest or maximum speed in a vehicle equipped with a constant mesh
gearbox. It is engaged when the dog clutch interferes with the smallest gear on the main shaft,
which is constantly meshed with the largest gear on the lay shaft. This gear enables efficient
highway driving and higher vehicle speeds.
Reverse Gear:
When dog clutch 1 moves towards the right, it meshes with gear D, leading to the rotation of the
output shaft.
Power transmission path: Engine shaft -> Clutch gear -> Gear 5 -> Lay shaft -> Gear 1 ->
Idler gear -> Gear D -> Output shaft.
The constant mesh gearbox's well-designed gear engagement system allows for efficient gear
shifting and smooth power transmission in different driving scenarios.
Advantages of Constant Mesh Gearbox
The various advantages of Constant Mesh Gearbox include:
o Compact Size: Constant mesh gearboxes are more space-efficient and compact in
comparison to sliding mesh gearboxes, contributing to better vehicle design and layout.
o Smooth Engagement: The constant mesh design allows for smoother gear engagement,
resulting in seamless and jerk-free transitions between gears, enhancing driving comfort.
o Silent Operation: The use of helical and double helical gears in the constant mesh
gearbox significantly reduces noise during gear shifts, creating a quieter and more
enjoyable driving experience.
o Reduced Wear and Tear: The continuous meshing of gears in the constant mesh
gearbox leads to less wear and tear, promoting improved durability and longevity of the
transmission system.
o Easy Gear Shifting: The constant mesh gearbox simplifies gear shifting for the driver,
requiring minimal effort and ensuring precise gear selection, making it user-friendly for
various driving conditions.
o Efficient Power Transmission: With constant gear engagement, the constant mesh
gearbox efficiently transfers power from the engine to the wheels, maximizing vehicle
performance and fuel efficiency.
o Wide Gear Ratio Range: The constant mesh gearbox offers a broader range of gear
ratios, allowing for better adaptation to varying driving conditions, such as city driving,
highway cruising, or off-road situations.
Disadvantages of Constant Mesh Gearbox
The disadvantages of the Constant Mesh Gearbox include:
o Double Declutching: Constant mesh gearboxes require double declutching during gear
changes, making the process more complex and demanding for the driver.
o Increased Noise: Compared to some other transmission systems, constant mesh
gearboxes can produce more noise during gear engagement, potentially affecting driving
comfort.
o Limited Gear Ratios: Constant mesh gearboxes may offer a limited range of gear ratios,
which could restrict their adaptability to different driving conditions.
 o Complexity in Design: The constant mesh gearbox's design involves intricate
components and mechanisms, potentially leading to increased manufacturing and
maintenance costs.
o Gear Synchronization: Achieving smooth gear synchronization without the use of
synchronizers can be challenging, leading to potential gear clash and wear.
Difference between Constant Mesh Gearbox and Sliding Mesh Gearbox
The following table lists the differences between constant mesh gearbox and sliding mesh
gearbox.
Aspect Constant Mesh Gearbox Sliding Mesh Gearbox
Gear Engagement Constantly meshed, even at idle Gears are sliding and meshed when engaged
Gear Changing Synchronized shifting Non-synchronized shifting
Gear Teeth Design All gears have dog teeth Gears have both dog teeth and clutch teeth
Complexity More complex design Simpler design
Noise and Vibration Lesser noise and vibration due to More noise and vibration during gear shifts
synchromesh
Driver Effort Requires less effort to shift gears Requires more effort to shift gears
Gear Gears mesh smoothly due to Gears may clash during shifting
Synchronization synchromesh
Applications Mostly used in modern vehicles Older vehicles and industrial applications
Efficiency Slightly lower efficiency due to added Slightly higher efficiency
parts
Application of Constant Mesh Gearbox
The constant mesh gearbox serves applications in the following vehicles:
o Farmer Trucks: Constant mesh gearboxes were commonly employed in farmer trucks,
providing them with reliable and efficient transmission systems for their agricultural
tasks.
o Two-Wheelers: Many two-wheeler vehicles, such as motorcycles and scooters, were
equipped with constant mesh gearboxes, offering smooth gear shifting and easy
handling.
o Heavy Duty Machinery: The constant mesh gearbox found its application in heavy-duty
machinery, providing robust and durable transmission systems to handle demanding
industrial operations [1].

The accuracy of the output of a gear depends on the accuracy of its material selection, design
and manufacturing. The correct manufacturing of a gear requires a number of prerequisite
calculations and design considerations.

1. Basic assumptions for the design Rotational assumption

  Input shaft rotate counter clock wise for a start and then the counter shaft clock
wise.
Operation and the environmental Conditions
 The design is based on Kombolcha atmospheric temperature at 28Co+273k=301k
 Steady load (means no shock) and the shaft and gear weight not considered.
 Service factor is taken for 24 hour per a day.
 Enclosed well lubricated gears.
2. The design consideration taken into account for gears design:

 Strength of the gear in order to avoid failure at staring torques or under dynamic
 Loading during running conditions.
 Gear teeth must have good wear characteristics.
 Selection of material combination.
 Proper alignment and compactness of drive
 Provision of adequate and proper lubrication arrangement.
 The speed reducer should operate safely and provide a safe environment for
people Near the machine
 Low cost is desirable
 Small size to reduce the space used.
 High reliability
 Low maintenance
 Smooth operation, low noise, low vibration gear.

2.1. Selecting the gear material

Gears are made of ferrous, nonferrous metals and non-metallic materials .In many cases of gear
operations wear resistance and not the strength is the basic operations. Under such circumstance,
Cast iron is the best gear material.
There are three poplar types of cast iron.
 Grey
 Malleable and
 Ductile
Grey cast iron is selected for our gear because;
 It is available in large quantities and produced in mass production.
 It can get any complex shape without involving costly medical.
 It has low notch sensitivity.
 It has good tensile properties.
  It has very low cost.
 The distinctive properties of cast iron result largely from its carbon content.
 The high carbon content makes molten iron very fluid, so that it can be poured
into intricate shapes.
 The precipitation of carbon during solidification counteracts normal shrinkage to
give sound sections.
 The presence of graphite in the metal provides excellent machine ability (even at
wear-resisting hardness levels), damps vibration, and aids boundary lubrication at
wearing surfaces.
Grey cast iron is used for automotive component such as cylinder block, brake drum, clutch plat,
cylinder plat and cylinder head, gear and housing gears. Grey cast iron specified by symbol FG
followed by ultimate tensile strength of 300N/mm2 [5].