DESIGN AND FABRICATION OF

PROGRESSIVE GEARBOX

A dissertation submitted in partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING

Submitted by

AMAL VENIS.W 81908144501

ANANTHA KUMAR.K 81908144502

Under the Guidance of

Dr.V.GOPALAKRISNAN

DEPARTMENT OF MECHANICAL ENGINEERING

SARANATHAN COLLEGE OF ENGINEERING
TRICHY-620012

ANNA UNIVERSITY OF TECHNOLOGY TIRUCHIRAPPALLI

TIRUCHIRAPPALLI – 620 024
APRIL-2011
 DECLARATION

I hereby declare that the work entitled “PROGRESSIVE GEARBOX “is

submitted in partial fulfillment of the requirement for the award of the degree in
B.E, Anna University of Technology Tiruchirappalli, is a record of the my own
work carried out by me during the academic year Jan 2011 –May 2011 under the
supervision and guidance of Prof.Dr.V.GOPALAKRISHNAN, Department of
Mechanical engineering, Saranathan College of engineering. The extent and source
of information are derived from the existing literature and have been indicated
through the dissertation at the appropriate places. The matter embodied in this
work is original and has not been submitted for the award of any other degree or
diploma, either in this or any other University.
Signature

AMAL VENIS.W
81908144501

ANANTHA KUMAR.K
81908144502
I certify that the declaration made above by the candidate is true.

SIGNATURE
Dr.V.GOPALAKRISHNAN
Professor,
Mechanical Engineering,
Saranathan College of engineering.
Trichy -12.

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 BONAFIDE CERTIFICATE

This is to certify that the dissertation entitled “PROGRESSIVE GEARBOX” is a bonafide work
carried out by
AMAL VENIS.W 81908144501
ANANTHA KUMAR.K 81908144502
under my direct supervision is submitted in partial fulfillment of the requirements for the award
of degree of Bachelor of Engineering in MECHANICAL ENGINEERING to Anna University
of Technology Tiruchirappalli, Tiruchirappalli – 620 024. No part of the dissertation has been
submitted for any degree/diploma or any other academic award anywhere before.

SIGNATURE
Dr.V.GOPALAKRISHNAN
SUPERVISOR

Forwarded by

SIGNATURE
S.CHINNATHAMBI
HEAD OF THE DEPARTMENT

INTERNAL EXAMINER EXTERNAL EXAMINER

3
 ACKNOWLEDGEMENT

We express our sincere thanks to Dr.Y.VENKATRAMANI Ph.D, Principal and

Prof V.NAGARAJAN, Director (Administration) Saranathan College of
Engineering, for permitting us to carry out this project.

We are much obliged to Prof. S.CHINNATHAMBI, B.E, M.Sc (Engg),

PGDBA, DCPA, DLL, Head of the Department of the Mechanical Engineering
for his constant support and encouragement.

We express our sincere thanks to our project guide Professor

Dr.V.GOPALAKRISHNAN for his constructive suggestions during the project
fabrication and completion of the project.

We are very thankful to our project co-ordinator Mr.SATHYANARAYANAN,

for his support and guidance throughout the course of this project.

We would like to thankful our workshop instructors for their valuable support
throughout our project

We would like to thank all our staff and technical assistants for their support and
help rendered by them in completing this project successfully.

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 ABSTRACT

This project mainly deals about design and fabrication of self progressing gear box. A
gear box is an assembly of gears which is used for controlling the speed and has many
applications widely, even in automobiles gear box is implemented and various improvements are
done day by day. One of the improvements done in gear box is auto changing. In our project a
prototype of this gearbox for auto changing for gears is done with the help of a governor
mechanism. The assembly consists of a set of gears connected to the motor through the governor.
The governor is attached to the driver shaft. At initial position there will be no engagement of
gears for power transmission. When the speed begins to increase in the driver shaft due to
presence of the governor the initial height reduces and the shaft moves and engages with the first
gear and power is transmitted to the driven shaft. As the speed further increase in speed will
cause the second gear to engage. And vice versa when the speed reduces and the driver shaft will
return to the initial position with the help of the spring. The design procedures, drawings for the
above mentioned project is given below.

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 TABLE OF CONTENT

CHAPTER NO: TITLE PAGE NO.

ABSTRACT v

LIST OF TABLES vi

LIST OF FIGURES vii

LIST OF SYMBOLS viii

1 INTRODUCTION 1

2 LITERATURE REVIEW

3 DESCRIPTION OF COMPONENTS 2

3.1 GEAR 2

3.2 GEAR BOX 10

3.3 GOVERNOR 12

4 PART DIAGRAM 13

5 ASSEMBLY DIAGRAM 14

6 WORKING PRINCIPLE 16

7 DESIGN CALCULATION 18

8 APPLICATIONS 22

9 ADVANTAGES 23

10 LIST OF MATERIAL 24

11 COST ESTIMATION 25

12 CONCLUTION 26

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 INTRODUCTION

A progressive gearbox is a gearbox which changes the gear according to speed variation.
This movement for the gears based on speed is done with the help of governor. Its main
function is to shift the gears in forward as speed increases and vice versa when the speed
decreases. The governor plays vital role in changing of gears. By using a prime mover
(Motor) and governor mechanism the forward and reverse motion of driving shaft is
achieved.

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 DESCRIPTION OF COMPONENTS

GEAR:

INTRODUCTION
Gears are toothed wheels used for transmitting motion and power from one shaft to
another when they are not too far apart and when constant velocity ratio is desired. In
comparison with belt, chain and friction drivers, gear drives are more compact, can operate
at high speeds and can be where precise timing is required. Also gear drives are used when
large power is to be transmitted. The force required to hold the gears in position is much less
than in an equivalent friction drive. This results in lower bearing pressure, less wear on the
bearing surface.

Advantages and Limitation of Gear Drive over Chain and Belt Drives
Advantages:
Since there is obtained no slip, so exact velocity ratio is obtained.
It is capable of transmitting larger power than of the belt and chain drives.
It is more efficient (up to 99%) and effective means of power transmission.
It requires less space as compared to belt and rope drives.
It can transmit motion at very low velocity, which is not possible with the belt
drives.
Limitations:
The manufacture of gears requires special tools and equipments.
The manufacturing and maintenance costs are comparatively high.
The error in cutting teeth may cause vibrations and noise during operations.

Definition of Gear
A circular body of cylindrical shape or that of the shape of frustum of a cone and of
uniform small width, having teeth of uniform formation, provided on its outer
circumferential surface, is called a gear or toothed gear or toothed wheel.

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 CLASSIFICATION OF GEARS
Gears may be classified in different manners as given below :
Classification based on the relative position of their shaft axis:
Parallel shafts
Examples: Spur gear, helical gear, rack and pinion and internal gears.
Intersecting shafts
Examples: Bevel gears and spiral gears.
Non-parallel, non-intersecting shafts
Examples: Worm, hypoid and spiral gears.
Classification based on the relative motion of the shafts:
Row gears: In this type, the motion of the shafts relative to each other is fixed.
Planetary and differential gears
Classification based on peripheral speed (v):
Low velocity gears - v < 3 m/s
Medium velocity gears - v = 3 to 15 m/s
High velocity gears - v > 15 m/s
Classification based on the position of teeth on the wheel:
Straight gears Herringbone gears
Helical gears Curved teeth gears
Classification on the type of gearing:
External gearing
Internal gearing
Rack and pinion
But from our subject point of view, gears are broadly classified into four groups,
viz., spur, helical, bevel and worm gears.
Spur gear (sometimes called straight spur gears) have teeth parallel to the axis of
rotation are used to transmit motion from one shaft to another parallel shaft.
Helical gears have teeth inclined to the axis of rotation. The double helical gears
connecting two parallel shafts are known as herringbone gears.
Bevel gears have teeth formed on conical surfaces. They are mostly used for
transmitting motion between intersecting shafts.

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 Worm gears consist of a worm and a wheel can be visualized as a screw and nut
pair. They are used to transmit motion between non-parallel non-intersecting shafts.
SPUR GEAR
In spur gears, the teeth are straight and parallel to the axis of the wheel. The gearing
so formed is called spur gearing. They are used to transmit rotary motion between parallel shafts
.This gearing may be internal or external. External gears rotate in opposite directions while
internal gears rotate in the same direction.

Terminology Used in Gears (Gear Nomenclature)

The various terms used in the study of gears have been explained below.
Pinion: A pinion is the smallest of two matting gears. The larger is often called the gear
or the wheel.
Pitch circle: It is an imaginary circle which by pure rolling action, would give the same
motion as the actual gear.
Pitch circle diameter: It is the diameter of the pitch circle. The size of the gear is usually
specified by pitch circle diameter. It is also called as pitch diameter.

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 Pitch point: It is a common point of contact between two pitch circles.
Pitch surface: It is the surface of the rolling discs which the meshing gears have replaced
at the pitch circle.
Pitch: Pitch of two matting gears must be same. It is defined as follows:
Circular pitch (pc):
It is the distance measured along the circumference of the pitch circle from a point on
one tooth to the corresponding point on the adjacent tooth.
πD
Circular pitch, pc =
z

Where D = Diameter of pitch circle, and

z = Number of teeth on the wheel
Diametral pitch (pd):
It is the ratio of number of teeth to the pitch circle diameter.
z
Diametral pitch, pd =
D

Module pitch (m) :

It is the ratio of the pitch circle diameter to the number of teeth.
D
Module, m=
z

Addendum circle (or Tip circle): It is the circle drawn through the top of the teeth and
concentric with the pitch circle.
Addendum: It is the radial distance of a tooth from the pitch circle to the top of the
tooth.
Dedendum circle (or Root circle): It is the circle drawn through the bottom of the circle.
Dedendum: It is the radial distance of a tooth from the pitch circle to the bottom of the
tooth.
Clearance: It is the radial distance from the top of the tooth to the bottom of the tooth, in
a meshing gear. A circle passing through the top of the meshing gear is known as clearance
circle.
Total depth: It is the radial distance between the addendum and the dedendum of a gear.
Total depth = Addendum + Dedendum
Working depth: It is the radial distance from the addendum circle to the clearance circle.
It is equal to the sum of the two meshing gears.

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 Tooth thickness: It is the width of the tooth measured along the pitch circle.
Tooth space: It is the width of the space between the two adjacent teeth measured along
the pitch circle.
Backlash: It is the difference between the tooth space and the tooth thickness along the
pitch circle.
Backlash = Tooth space – Tooth thickness
Face width: It is the width of the gear tooth measured parallel to its axis.
Top land: It is the surface of the top of the tooth.
Bottom land: The surface of the bottom of the tooth between the adjacent fillets.
Face: Tooth surface between the pitch circle and the top land.
Flank: Tooth surface between the pitch circle and the bottom land including fillet.
Fillet: It is the curved portion of the tooth flank at the root circle.
Pressure angle (φ): It is the angle between the common normal to two gear teeth at the
point of contact and the common tangent at the pitch point. The standard pressure angles are
14.5˚and 20˚.
Path of contact: It is the path traced by the point of contact of two teeth from the
beginning to the end of the engagement.
Length of path of contact: It is the length of the common normal cutoff by the
addendum circles of the wheel and pinion.
Arc of contact: It is the path traced by a point on the pitch circle from the beginning to
the end of arrangement of a given pair of teeth. The arc of contact consists of two parts. They are
:
Arc of approach : It is the portion of the path of contact from the beginning of the
engagement to the pitch point.
Arc of recess : It is the portion of the path of contact from the pitch point to the end of
the engagement of a pair of teeth.
Velocity ratio: It is the ratio of speed of driving gear to the speed of the driven gear.
NA zb
ί = NB=za

where NA and NB = Speeds of driver and driven respectively, and

zA and zB = Number of teeth on driver and driven respectively.

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 Contact ratio: The ratio of the length of arc of contact to the circular pitch is known as
contact ratio. The value gives the number of pairs teeth in contact.
LAW OF GEARING
The law of gearing states that for obtaining a constant velocity ratio, at any instant of
teeth the common normal at each point of contact should always pass through a pitch point,
situated on the line joining the centers of rotation of the pair of matting gears.
The law of gearing states the condition which must be fulfilled by the gear tooth
profiles to maintain a constant angular velocity ratio between two gears. This is the fundamental
condition which must be satisfied while designing the profiles of the teeth of gear wheels.

FORMS OF GEAR TOOTH PROFILE

Two curves of any states that fulfill the law of gearing can be used as the profile of
teeth. If profile of the teeth of one of the matting gears is arbitrarily chosen and the profile of
teeth of the other gear is determined so as to satisfy the law of gearing, such teeth are known as
conjugate teeth. Gears having conjugate teeth can be successfully used for transmitting motion
but they are difficult to manufacture as special devices are used for this purpose which are costly.
So conjugate teeth are not much common in use
Therefore the common forms of teeth profiles used in actual practice are:

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 Involute tooth profile and Cycloidal tooth profile
Involute Tooth Profile
An involute is defined as the locus of a point on a straight line which rolls without
slipping on the circumference of a circle. Also, it is the path traced out by the end of a piece of
taut cord being unwound from the circumference of a circle. The circle on which the straight line
rools or from which the cord is known as the base circle.
Cycloidal Tooth Profile
A cycloid is the curve traced by a point on the circumference of a circle which rolls
without slipping on a straight line. It is difficult to manufacture as two curves hypo and
epicycloid are required. Center distance should not vary. Less wear and tear as concave flank
makes contact with convex flank.
STANDARD SYSTEMS OF GEAR TOOTH
The American gear manufacturers Association (AGMA) and National Standards
Institute (ANSI) standardised the following four forms of gear teeth depending upon the pressure
angle.
14.5˚ composite system,
14.5˚ full depth involute system,
20˚ full depth involute system, and
20˚ stub involute system
In actual practice, the 20˚ involute system is widely used.
Advantages of 14.5˚ Involute System
It provides smooth and noiseless operation.
It has stronger tooth.
Advantages of 20˚ Involute System
It reduces the risk of undercutting.
It has stronger tooth with a higher load carrying capacity.
It has greater length of contact.

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 STANDARD PROPORTIONS OF GEAR SYSTEMS
The table shows the standard proportions in module for the gear systems.
S.No. Particulars 14.5˚composite or full 20˚ full depth 20˚ stub
depth involute involute system involute
system system

1 Addendum 1m 1m 0.8 m
2 Dedendum 1.25 m 1.25 m 1m
3 Working depth 2m 2m 1.6 m
4 Minimum total 2.25 m 2.25 m 1.8 m
depth
5 Tooth 1.5708 m 1.5708 m 1.5708
thickness m
6 Minimum 0.25 m 0.25 m 0.2 m
bottom clearance
7 Fillet radius at 0.4 m 0.4 m 0.4 m
root

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 GEAR BOX

INTRODUCTION
We know that machine tools like lathe, milling machine, etc., require a wide range of
spindle speeds. Because a machine tool is adoptable for cutting different types of metals having
different properties using varying grades of cutting tools on work pieces of different diameters.
Thus the provision of variable spindle speed is necessary in order to meet different requirements.
The various methods used for obtaining different speeds of machine tool spindle are as follows :
By using a gear box mechanism,
By using a cone pulley arrangement,
By using a variable speed electric motor, and
By hydraulic operation.
Among these methods, the gear box method is very popularly used.
REQUIREMENTS OF A SPEED GEAR BOXES
A speed gear box should have the following requirements :
It should provide the designed series of spindle speed.
It should transmit the required amount of power to the spindle.
It should provide smooth silent operation of the transmission.
It should have simple construction.
Mechanism of speed gear boxes should be easily accessible so that it is easier to
carry out preventive maintenance.
NECESSITY OF A GEAR BOX
To regulate torque by selecting the appropriate speed range.
To regulate vehicle speed at which maximum torque is available.
To balance the tractive effort with the sum of the various forces tending to oppose
the motion.

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 TYPES OF GEAR TRANSMISSION
Gear Boxes are generally classified as
Selective type
Progressive type
Epicyclic or Planetary type
Selective type is further classified as
Sliding mesh
Synchro mesh
Constant mesh
Other special classifications are
Over drive
Chrysler semi-automatic
Automatic
Hydromatic drive
Torque converter gear box.
SLIDING MESH GEAR BOX
It is the oldest and simplest form of gear box. Sliding type gear boxes are quite
commonly used in general purpose machine tools. In order to mesh gears on the main shaft with
appropriate gears on the spindle shaft for obtaining different speeds, they are moved to the right
or the left. It derives its name from the fact that the meshing of the gears takes place by sliding of
gears on each other.
CONSTANT MESH GEAR BOX
It derives its name from the fact that all the gears whether of the main shaft are in
constant mesh with each other. It is also known as a silent or quite gear box. It gives a quieter
operation and makes gear changing easier by employing helical gears for the constant mesh. In
order to connect the required gear wheel by means of teeth on the side of the gear wheel, a
separate sliding member is employed.

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 GOVERNOR

 The function of a governor is to automatically maintain the speed of an engine within

specified limit whenever there is a variation in load.
 If the load on the engine increases its speed decreases. So it becomes necessary to
increase the fuel supply by opening the throttle valve.
 On the other hand, when the load on the engine decreases, its speed increases and the fuel
supply is to be decreased by closing the throttle valve.
 Thus the governor keeps the speed of the engine within certain limit by regulating the
fuel as per load requirements.

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Centrifugal governor

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 WORKING PRINCIPLE

The working of this gearbox is same as ordinary gearbox except for the gear shifting
automatically as the speed increases.
As initial in rest position no gears will be engaged and hence no power transmission for
the driving to the driven wheel is obtained.
Then when the driving shaft begins to rotate due to the centrifugal force the governor
begins to expand.
Since the governor is attached to the driving shaft the sliding shaft also slides towards the
governor.
As the driving shaft attains a particular speed the first set of gears will begin to engage
and power is transmitted to the driven shaft.
Even further improvement in speed ill cause the 2nd set of gears to engage.
Then as the speed reduces due to the spring force the sliding shaft will move away from
the governor.
And it finally disengages from all gears and comes to neutral position.

NEUTRAL POSITION

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FIRST GEAR ENGAGEMENT

SECOND GEAR ENGAGEMENT

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 DESIGN CALCUALTION

To design a gear drive with no of teeth on pinion as 27 and no of teeth on gear 33 the centre

distance between two shafts are 60mm.

Total no of teeth on pinion and gear:

m( z1  z 2 ) m( 27  33)
a => 60= => m = 2mm
2 2

Calculation of face width:

Face width (b) = 5m = 5*2 = 10mm

Pitch circle diameter & velocity:

Pitch circle diameter of pinion (D1) = m*z1 = 2*27 = 54mm

Pitch circle diameter of gear (D2) = m*z2 = 2*33 = 66mm

𝜋∗𝐷1 ∗𝑁1 𝜋∗0.054∗200

Velocity (v) = = = 0.57 m/s.
60 60

Addedendum = D1+2*m
=54+2*2 = 58mm

Dedendum = D1 - 2(m+c)
Clearance c = 0.25 * m = 0.25 * 2 = 0.5mm

= 54+2(2+0.5)
=49mm

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 SPECIFICATION OF GEAR

Dimensions Pinion Gear

Module 2 mm 2mm

Pitch circle diameter 54mm 66mm

Width of tooth 10 mm 10mm

Addendum circle diameter 58mm 70 mm

Dedendum circle diameter 49 mm 61 mm

No of teeth 27 33

Clearance 0.5 mm 0.5 mm

Gear ratio = 1.22

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 SPECIFICATION OF GOVERNOR

R
The arm length l = 80 mm
The initial height of the governor h = 61.28mm
Initial radius at rest r = 51.42mm
Initial angle = 40°
The mass attached m = 0.5kg
H

CALCULATION FOR GOVERNOR

For 1st gear: value of h=53.78mm, r = 59.22mm

Stiffness value of spring = 50N/m
𝑚∗𝑔+𝑠
Fc * h = ( )*r
2
Fc = m*w2*r

2∗𝜋∗𝑁 2 3∗9.81+50
0.5 * ( ) *0.059*0.054 = ( )* 0.059
60 2
N = 366.24 rpm

For 2nd gear: value of h=41.28mm, r = 68.53mm

Stiffness value of spring = 50N/m
𝑚∗𝑔+𝑠
Fc * h = ( )*r
2
Fc = m*w2*r

2∗𝜋∗𝑁 2 3∗9.81+50
0.5 * ( ) *0.069*0.041 = ( ) * 0.069 N = 420.31 rpm
60 2

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 OPERATION SPECIFICATION

POSITION INPUT HEIGHT OF RADIUS OF OUTPUT SPEED

SPEED GOVERNOR GOVERNOR

NEUTRAL 0 61.28 51.42 0

ST
1 GEAR 366.22 53.78 59.22 300

ND
2 GEAR 420.31 41.28 68.53 514

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 ADVANTAGES

 Simplicity in gear changing.

 No need for providing linkages and lever for gear changing.
 Manual operation is avoided.
 Space is reduced.

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 APPLICATION

 In automobile for automatic gear changing.

 In gearbox used in machining and drilling.

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 BILL OF MATERIALS

Component Specification Material Qty

Motor 1/4 Hp - 1.00

Gears Teeth 27,33 steel 4.00
Governor 25x6x600mm Mil steel 1.00
Shaft 16x600mm Mild steel 1.00
Frame L-angle 25x10x600mm Mil steel 4.00
Bushes 32x30mm Mil steel 4.00
Bolt with Nuts M12 x 60 Mil steel 10.00
M12 x 75 Mil steel 3.00
WASHER M12 plate washer Mil steel 15.00

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 COST ESTIMATION

Component Description COST

Raw Material Cost
Motor 1/4 Hp 500
Motor clamp 5" Size 45
L angle 25x6x6000mm 298
Shaft ø16 mm 165
Bushes Ø32 mm 25
Gears Spur gears 350
MS Flat 25x6x600 85
spring Open coil 10
Regulator - 60
Fasteners All sizes 15
wiring 3 core cable 75
Machining Cost
Cutting To desired length 100
Gear and shaft Welding and machining 170
Bushes Machining & Drilling 50
Frame Welding and Drilling 200
Governor Welding and Drilling 100
Miscellaneous 500
TOTAL 3000

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 CONCLUSION

A brief explanation about the progressive gearbox is given in the above. Even though these types
of gearboxes are only introduced in latest automobile vehicles but in the future this gearbox can
be the dominating one. Even though lot of improvement can be done our project only a prototype
is don for learning purpose. And I finally like to thanks all who helped me in completing this
project.

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