11 final drive

Feb 17, 2016Download as pptx, pdf11 likes22,357 views

The rear axle final drive (1) transmits power at a 90 degree angle from the transmission and (2) reduces the engine speed to provide the transmission's top gear ratio. (3) Cars typically use a final drive ratio of around 4:1. Bevel, hypoid, and worm gears are commonly used in final drives to achieve the necessary functions.

Rear Axles Final-drive
The rear axles final drive
(i) Transmits the drive through a angle of 90degrees, and
(ii) Gears down the engine revolutions to provide a
‘direct top’ gearbox ratio.
(iii) In the case of cars a final drive ratio of approximately
4 : 1 is used.
(iv) Bevel or worn gears are employed to achieve the
various functions of the final drive.

TYPES OF FINAL DRIVES
1. Bevel Gears
– Straight Bevel.
– Spiral Bevel.
2. Hypoid Gear
3. Worm and Wheel Drive

Bevel Gears
• The geometry of a bevel gear
layout, which represents two
friction cones ‘A’ forming the
crown wheel and ‘B’ the pinion.
• For avoidance of slippage and
wear, the apex of the pinion must
coincide with the centre line of the
crown wheel.
• It is necessary to mount the gear in
the correct position so that angle
of the bevel is governed by the
gear ratio.

Types of Bevel Gear.
1. Straight Bevel.
2. Spiral Bevel.

Backlash In Gears
• Backlash is most commonly created by cutting
the teeth deeper into the gears than the ideal
depth.
• Another way of introducing backlash is by
increasing the center distances between the
gears.
• Standard practice is to make allowance for half
the backlash in the tooth thickness of each gear.

Straight Bevel
• The tapered teeth, generated from the centre, are machined on the case-
hardened steel gears and then ground together to form a ‘mated pair’.
• The position of the crown wheel relative to the pinion determines the
direction of rotation of the axle shaft.
• For correct meshing and for setting the clearance between the teeth
(backlash), adjusters in the form of distance pieces, shims or screwed rings
are used.
• When backlash is too small, expansion results due to heat and wear is
caused by lack of lubrication.
• On the other hand excessive backlash produces slackness and noise.
• Each manufacturer recommends a suitable backlash, but it is generally in
the region of 0.15 mm for cars and 0.25 mm for heavy vehicles.

Spiral Bevel
• Although the straight bevel is cheaper and
mechanically efficient, the meshing of the gears
causes an unwanted noise, which has been
reduced by introducing a helical form of tooth.
• Figure illustrates the construction of the gear, A
number of teeth are generated from the centre of
the crown wheel, and form a left-handed spiral in
the case of the pinion.

Hypoid Gear
• This type of gear is the commonly used now a days.
• The pinion axis of this gear is offset to the centre line of the crown wheel.
• Although the gear can be placed above or below the centre, but in cars it is
always placed below to allow for a lower propeller shaft so that a reduction
in the tunnel height is possible.
• If the axis is lowered, the tooth pitch of the pinion increases, so that for a
given ratio, the pinion diameter can be larger (30 percent for normal offset).
• This enables the use of a stronger gear specifically on commercial vehicles.

Worm and Wheel Drive
• Since this drive is expensive, it is rarely used nowadays as a
final drive on light vehicles, but is still used on heavy vehicles.
• However, this type of gear has a number of other applications
on motor vehicles.
• It can be employed to provide a very quiet and long-lasting
gear, but efficiency is less than the bevel (94 percent against 98
percent).
• This type of gear provides a large reduction in a small space.

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The cylinder liner is cast separately from the cylinder block and can be made of a different, more durable material like a nodular cast iron alloyed with chromium, vanadium, and molybdenum. While the cylinder block is made of grey cast iron, the liner wears with use and may need replacement, unlike the cylinder jacket that lasts the life of the engine. Piston rings are split rings that fit into grooves on the outer diameter of engine pistons to seal the combustion chamber.

10 cylinder liner and ringsshaikusmanshag

This document discusses various components of internal combustion engines including pistons, piston rings, connecting rods, and their materials and functions. It provides details on piston design types, materials, manufacturing processes, ring materials and compositions. It also describes connecting rod designs, materials, measurements and installation procedures. The key components and their roles in transforming combustion energy to rotational motion are summarized.

9 upset forging of valvesshaikusmanshag

8 gudgeon pinshaikusmanshag

7 connecting rodshaikusmanshag

6 crank shaftshaikusmanshag

5 cylinder headshaikusmanshag

The cylinder head determines key engine properties like power output, torque, and emissions. Cylinder heads require materials with high mechanical properties above 150°C due to the complex shapes and high stresses during operation. For passenger cars, aluminum is commonly used due to its properties, while cast iron is used for larger engines. Modern cylinder heads, especially for direct injection diesel engines, require alloys with high tensile strength, creep resistance up to 250°C, thermal conductivity, and ductility to withstand thermal stresses. Common casting methods include sand casting, permanent mold casting, lost foam, and pressure die-casting, using cast iron or aluminum alloys.

4 engine blockshaikusmanshag

The document discusses the manufacturing process of engine components. It describes the steps as: 1. Casting of the engine block using conventional or expendable patterns. Other components like cylinder heads, crankshafts and connecting rods are also cast or forged. 2. The castings undergo machining and heat treatment processes. Pistons are manufactured through gravity casting, squeeze casting, and then machined. 3. Valves are upset forged and heat treated to improve strength and wear resistance. Cylinder liners and piston rings are also manufactured to complete the engine assembly.

3 surface hardeningshaikusmanshag

Case hardening or surface hardening involves hardening just the surface of a metal part to create a thin hardened outer "case" while leaving the inner core soft. There are several methods for case hardening, including direct hardening using austenitizing and quenching, as well as diffusion hardening techniques like carburizing (adding carbon via heating in a carbon-rich environment), nitriding (diffusing nitrogen into the surface at high heat), and cyaniding (dipping in a heated cyanide bath). Carburizing, the most common diffusion method, involves packing parts in charcoal and heating to diffuse carbon atoms into the surface before quenching.

3 forgingshaikusmanshag

Forging is the process of shaping metals by applying compressive forces. It can be done either hot or cold. Common forging operations include drawing, piercing, punching, and swaging. Forging machines include drop hammers, power hammers, mechanical presses, and hydraulic presses. Closed-die forging uses dies to precisely shape parts, while open-die forging uses simpler dies. Proper die material selection and coatings can increase die life. Forging results in an elongated grain structure and improved mechanical properties compared to casting.

2 basics of castingshaikusmanshag

2 introduction to cim. pptxshaikusmanshag

Computer integrated manufacturing (CIM) is an approach that uses computers to control the entire manufacturing process. In a CIM system, functions like design, planning, cost accounting, and inventory control are linked through computers to factory floor functions like materials handling and operations management to provide direct monitoring and control of all operations. CIM allows processes to exchange information and initiate actions, enabling faster, less error-prone manufacturing and the creation of automated processes. The benefits of CIM include improved quality, shorter new product times, minimized costs and flow times, increased competitiveness, flexibility, productivity and customer service.

3 numerical controlshaikusmanshag

The document provides an overview of numerical control (NC) and computer numerical control (CNC) machines. It discusses: 1) The historical development of NC from mechanized production equipment to programmable automation using NC, PLCs, and robots. 2) The basic definition and components of an NC machine, including the numerical controller, NC code, and interactions between the operator and machine. 3) The main components of NC machines - the machine control unit, machine tool, and various control units. It also discusses different types of machine control units. 4) Key aspects of NC motion control including point-to-point and continuous path control, open and closed loop systems, and different

5 accuracy and productivityshaikusmanshag

This document discusses methods for improving machine accuracy and productivity. It focuses on tool deflection, lead screw accuracy, and thermal deformation for improving accuracy. For productivity, it examines actual cutting time, idle time, loading/unloading time, and tool changing time. The document also provides an overview of special tool holders, describing the main parts of tool holders and different types like boring heads, chucks, and adapters. It emphasizes the benefits of balanced, high-accuracy tool holders for optimizing performance on CNC machines.

4 tooling in cncshaikusmanshag

This document discusses tooling for CNC machines, including cutting tools made of materials like high-speed steel, tungsten carbide, and ceramic. It also describes design features of CNC tooling like accuracy, flexibility, and rigidity. Finally, it covers automatic tool changers, which allow CNC machines to change tools through program instructions by rotating a tool magazine or drum to replace old tools with new ones.

6 blushaikusmanshag

This document discusses the basics of CNC machines including leadscrews, basic length units (BLU), and converting rotational motor motion to linear motion using pitch and teeth per inch. It provides an example of calculating pulse rate and count given a machine's BLU, feed rate, and distance to move. Open and closed loop controls are mentioned along with advantages of CNC like easier programming, storage, changes, avoiding errors, and producing complex geometries as cheaply as simple ones.

3 tyre typesshaikusmanshag

This document discusses different types of tires. There are two main types - tubed tires which have an inner tube, and tubeless tires which do not have an inner tube. Tubeless tires have advantages like lesser weight, better cooling, lower rolling resistance, and more comfortable ride. The document also describes different tire constructions - cross-ply/bias ply tires which have fabric plies laid across each other at alternating angles, radial ply tires which have fabric arcs from bead to bead at 90 degree angles, and belted bias ply tires which have belt plies reinforced with wire. Radial ply tires provide benefits like better shock absorption and fuel efficiency compared to cross-ply tires.

1 wheelsshaikusmanshag

The document summarizes wheels and tires. It discusses the requirements of automobile wheels, including being strong, balanced, lightweight, and easy to remove/mount. Standard wheels are steel, while some vehicles use aluminum or magnesium alloy wheels. Valve stems allow inflation/deflation and retain air. Wheel studs and nuts attach wheels to hubs using correct torque for safety. Common wheel types include steel, alloy, spoke, divided, and split rims. Custom wheels come in aluminum variants and differ in offset for handling characteristics.

3 tyre materialsshaikusmanshag

The document discusses the materials used in car tires, including nylon, polyester, rayon, carbon black, and aramid fibers for the carcass and belts. It also discusses the components of tires like raw rubber, steel, and synthetic rubber. The aspect ratio and tire specifications are explained. Factors that affect tire life and common tire issues are outlined. The manufacturing of pneumatic tires filled with compressed air is also briefly discussed.

Cylinder liner &materialsshaikusmanshag

10 cylinder liners and piston ring manufacturingshaikusmanshag

10 cylinder liner and ringsshaikusmanshag

9 upset forging of valvesshaikusmanshag

8 gudgeon pinshaikusmanshag

7 connecting rodshaikusmanshag

6 crank shaftshaikusmanshag

5 cylinder headshaikusmanshag

4 engine blockshaikusmanshag

3 surface hardeningshaikusmanshag

3 forgingshaikusmanshag

2 basics of castingshaikusmanshag

2 introduction to cim. pptxshaikusmanshag

3 numerical controlshaikusmanshag

5 accuracy and productivityshaikusmanshag

4 tooling in cncshaikusmanshag

6 blushaikusmanshag

3 tyre typesshaikusmanshag

1 wheelsshaikusmanshag

3 tyre materialsshaikusmanshag

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11 final drive

1. Final-drive or Rear Axles Final-drive

2. Rear Axles Final-drive The rear axles final drive (i) Transmits the drive through a angle of 90degrees, and (ii) Gears down the engine revolutions to provide a ‘direct top’ gearbox ratio. (iii) In the case of cars a final drive ratio of approximately 4 : 1 is used. (iv) Bevel or worn gears are employed to achieve the various functions of the final drive.

3. TYPES OF FINAL DRIVES 1. Bevel Gears – Straight Bevel. – Spiral Bevel. 2. Hypoid Gear 3. Worm and Wheel Drive

4. Bevel Gears • The geometry of a bevel gear layout, which represents two friction cones ‘A’ forming the crown wheel and ‘B’ the pinion. • For avoidance of slippage and wear, the apex of the pinion must coincide with the centre line of the crown wheel. • It is necessary to mount the gear in the correct position so that angle of the bevel is governed by the gear ratio.

6. Types of Bevel Gear. 1. Straight Bevel. 2. Spiral Bevel.

7. Backlash In Gears • Backlash is most commonly created by cutting the teeth deeper into the gears than the ideal depth. • Another way of introducing backlash is by increasing the center distances between the gears. • Standard practice is to make allowance for half the backlash in the tooth thickness of each gear.

8. Straight Bevel • The tapered teeth, generated from the centre, are machined on the case- hardened steel gears and then ground together to form a ‘mated pair’. • The position of the crown wheel relative to the pinion determines the direction of rotation of the axle shaft. • For correct meshing and for setting the clearance between the teeth (backlash), adjusters in the form of distance pieces, shims or screwed rings are used. • When backlash is too small, expansion results due to heat and wear is caused by lack of lubrication. • On the other hand excessive backlash produces slackness and noise. • Each manufacturer recommends a suitable backlash, but it is generally in the region of 0.15 mm for cars and 0.25 mm for heavy vehicles.

10. Spiral Bevel • Although the straight bevel is cheaper and mechanically efficient, the meshing of the gears causes an unwanted noise, which has been reduced by introducing a helical form of tooth. • Figure illustrates the construction of the gear, A number of teeth are generated from the centre of the crown wheel, and form a left-handed spiral in the case of the pinion.

12. Hypoid Gear • This type of gear is the commonly used now a days. • The pinion axis of this gear is offset to the centre line of the crown wheel. • Although the gear can be placed above or below the centre, but in cars it is always placed below to allow for a lower propeller shaft so that a reduction in the tunnel height is possible. • If the axis is lowered, the tooth pitch of the pinion increases, so that for a given ratio, the pinion diameter can be larger (30 percent for normal offset). • This enables the use of a stronger gear specifically on commercial vehicles.

14. Worm and Wheel Drive • Since this drive is expensive, it is rarely used nowadays as a final drive on light vehicles, but is still used on heavy vehicles. • However, this type of gear has a number of other applications on motor vehicles. • It can be employed to provide a very quiet and long-lasting gear, but efficiency is less than the bevel (94 percent against 98 percent). • This type of gear provides a large reduction in a small space.

11 final drive

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