Beruflich Dokumente
Kultur Dokumente
College of Engineering
Department of Mechanical Engineering
Junior Project (MENG 290)
Gear Box
Transmission Fundamentals
Bashar Al-Tobul
Hammam Mohamed
Mahmoud Islam Elghoneimy
Salaar Shakeel
20125667
20123973
20124754
20122385
Semester II 2013/2014
Course Instructor: Dr. Noaman Bekheet
May 23, 2014
Table of Content |
Abstract.3
Introduction..4-9
Design Calculations and Drawings..9-14
Gearbox Operation.15-18
Comments and Conclusions.19
Appendix20
Reference.20
Acknowledgment.20
List of Figures |
Figure1 Spur gear.....5
Figure 2 Helical gear......6
Figure 3 Bevel gear...7
Figure 4 Worm gear....7
Figure 5 First Gear..15
Figure 6 Second Gear16
Figure 7 Third Gear.17
Figure 8 Fourth Gear.18
Figure 8 Reverse Gear..18
Figure 9 Stress Machine.20
The free-hand sketches and the AutoCAD drawing are attached to the report
1.0 Abstract |
The objective of this project is to fully understand how a gearbox operates
and what the role of each component inside it is. Likewise, the dimensions of each
components are measured. The gearbox 5 transmissions are explained in details with
figures. Moreover, free hand sketches and AutoCAD drawings are attached for
further explanation. Difficulties faced during the project are also mentioned and
solutions and improvements are discussed.
2.0 Introduction |
A gear is a machine element used to transmit motion between rotating
shafts/wheels when the center distance between the shafts is not too large. They
provide a positive drive, maintaining exact velocity ratios between driving and driven
shafts.
A transmission is a speed and power changing device installed at some point
between the engine and driving wheels of the vehicle. It provides a means for
changing the ratio between engine rpm (revolutions per minutes) and driving wheel
rpm to best meet each particular driving situation. Given in order to get smooth
starts and have power to pass and climb hills, a power ratio must be provided to
multiply the torque and turning effort of the engine. Also required is a speed ration
to avoid the need for extremely high engine rpm at high road speed. The
transmission is geared to perform these functions.
Power transmission gears are usually made from chromium molybdenum steel
which provides good toughness and resistance to wear. Some (low power) gears are
made from sintered metal (powered metal). Non-power gears can be made of
almost any material including composites for quieter running non lubricated
arrangements.
Most gears are run lubricated either by regular maintenance lubrication or by
being run semi submersed in oil or spray lubricated.
Spur Gear
This is the most common type
of gear tooth shape, and
would be fitted in the
accessory gearbox of an
engine. The gear can be
parallel to each other. Spur gears may be noisy owing to the impact of the
teeth upon each other as they rotate.
Helical Gear
This is a smoother, less noisy running gear than the spur gear, the teeth are
cut on a curve or helix, which produces a sliding engagement of the teeth, and more
than one tooth is in engagement at any one time. A disadvantage of this gear for is
that it produces a heavy axial load. This disadvantage can be eliminated by using
double helical gears, with the teeth being cut in an opposite helix. An advantage of
this type of gear is that it can accept and transmit a higher loading than a spur gear
of the same size. Helical gears might be fitted in the reduction gearbox of a turbo
prop engine or in the gearbox of an ordinary car.
Bevel Gear
Worm Gear
This gear form is used where there is a large resistance to turning,
and a large reduction in speed is required. The worm teeth are
similar to a multi start thread, and are cut at an angle or on the
skew, in which case the gear may be called a skew gear.
Figure 4: Worm Gear
sensors,
pneumatics,
processors
and
actuators to
Bicycle gearing: Bicycles usually have a system for selecting different gear
ratios. There are two main types: derailleur gears and hub gears. The
derailleur type is the most common, and the most visible,
using sprocket gears. Typically there are several gears available on the rear
8
sprocket assembly, attached to the rear wheel. A few more sprockets are
usually added to the front assembly as well. Multiplying the number of
sprocket gears in front by the number to the rear gives the number of gear
ratios, often called "speeds".
The type of gearbox used in this project is a manual Nissan car gearbox. The main
specification of the gear box we selected consists of main shaft, counter shaft, and
housing. Gears are placed in the main shaft and counter shaft to transmit the
motion, whereas bearings to hold and support the shafts inside the housing. The
selected gearbox has specifications of helical and spur gearings.
Gearbox
importance appears in transmitting the work output from the pistons to the car
wheels. Owing to the gear ratios, gears such as reverse gear, low gear, second gear,
high gear, & overdrive rotate in different rotational speeds. For example in high gear,
the gear ratio is 1 to 1, thus the output shaft turns at the same speed as the
crankshaft.
The objective of this project is to illustrate how a gearbox works and show the
function of each component inside it.
Part Name
Quantity
Calculations
Picture
Clutch Shaft
C.I.
Steel
Steel
10
Material
2nd gear
3rd gear
1st gear
4th gear
= 33
= 75
= 0.44
= 7.14
= 2.27
= 2.630
Steel
= 28
= 105
= 0.2667
= 11.78
= 3.750
= 4.338
Steel
= 36
= 120
= 0.30
= 10.47
= 3.33
= 3.857
Steel
= 16
= 70
= 0.229
= 13.74
= 4.367
= 5.05
Steel
11
Steel
Reverse Idler
C.I.
10
Countershaft
C.I.
11
Countershaft gear
Steel
12
12
Steel
13
Reverse gear
Steel
14
Bearing
Steel
13
15
Drive gear
Steel
16
Housing
C.I
14
36
( = 12 = 1)
15
4.2 Second Gear: again when the clutch connects the motion to the clutch gear,
the counter shaft is directed to transmit the motion to the 2 nd gear input,
hence the 2nd gear rotates leading to the drive shaft to rotate with 2.4 to 1
33
2.4
1
16
4.3 Third Gear: as dog clutch clutches the 3rd gear of 20 mm in diameter, the
motion passes through the counter shaft leading to the drive shaft to gear
28
1.4
1
17
4.4 Fourth Gear: Owing to the straight pass of motion, the gear ratio of the 4 th
gear becomes 1 to 1; the driven gear is the same as the driving gear.
4.5 Reverse Gear: Though, the motion of the reverse gear is similar to the first
gear, the motion of delivered to the drive shaft is in the opposite direction.
This happens due to the reverse idler which exists between the main shaft
and the countershaft.
18
A gearbox was bought and disassembled and then it was discovered that the
gearbox was automatic and it had to be left and another one had to be
brought instead. 3 weeks were lost for this problem.
Press machine (Appendix 1) was used to dislocate the case out of the main
shaft.
For future improvements for the following batch that they should stick to the
schedule so that they dont run out of time.
Finally, the objective of the project is successfully accomplished; the gearbox
functionality is known and the role of each component inside it is fully
understandable.
19
6.0 Appendix |
This figure shows the stress machine used to dislocate the case out of the shaft:
7.0 References |
[1] Lahue, K. C., Petersen's big book of auto repair, In-text: (Lahue, 1976.)
[3] Brain, M., HowStuffWorks "How Sequential Gearboxes Work", Intext: (Brain, 2014), Bibliography: Brain, M, and Accessed 27 May 2014.
8.0 Acknowledgment |
The student who helped us in the workshop is Muslim Abdulkayoum Saed 20124138
20