DESIGN AND ANALYSIS OF 6 SPEED

GEARBOX

21MEC301P – DESIGN OF MECHANICAL SYSTEMS

A PROJECT REPORT

Submitted by

SURYA KUMAR S (RA2211054040005)

Under the guidance of

Dr. M. KAMATCHI HARIHARAN M.E., Ph.D.,

(Assistant Professor (S.G), Department of Mechanical Engineering)
in partial fulfillment for the award of the degree
of

BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING
of
FACULTY OF ENGINEERING AND TECHNOLOGY
 SRM Institute of Science and Technology
(Deemed to be University Under Section 3 of UGC Act, 1956)

BONAFIDE CERTIFICATE

Certified that this project titled “Design and Analysis of 6 s p e e d

gearbox” is the Bonafide work of “SURYA KUMAR S (RA2211054040005)”,
who carried out the project work under my supervision. Certified further, that to
the best of my knowledge the work reported herein does not form any other
project report or dissertation on the basis of which a degree or award was
conferred on an earlier occasion on this or any other candidate.

SIGNATURE SIGNATURE

Dr. M. KAMATCHI HARIHARAN M.E., Ph. D Dr. R. RAJARAMAN, M.E., Ph.D.

GUIDE HEAD OF THE DEPARTMENT

ASSISTANT PROFESSOR (S.G) DEPT. OF MECHANICAL

ENGINEERING DEPT. OF MECHANICAL ENGINEERING

Submitted for the Viva-Voce held on:

Signature of the Internal Examiner-1 Signature of the Internal Examiner-2

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 ACKNOWLEDGEMENT

We express our humble gratitude to the management for the facilities extended for
the project work.

We extend our sincere thanks to the Dean Dr. C V Jayakumar, Vice Principal -
Academics Dr.C.Gomathy and Vice Principal- Examinations Dr.S.Karthikeyan for
their invaluable support.

We wish to thank Dr.R.Rajaraman, M.E., Ph.D., Professor & Head, Department of

Mechanical for his valuable suggestions and encouragement throughout the period
of the project work.

We are extremely grateful to our Project Coordinator Dr.Kamatchi Hariharan M,

M.E., Ph.D., Assistant Professor, Department of Mechanical for leading and
helping us to complete our course. He provided us the freedom and support to
explore the research topics of our interest.

We sincerely thank our management, all Mechanical faculty members, staff and
fellow students who have directly or indirectly helped our project.

Finally, we would like to thank our parents, our family members and friends for
their unconditional love, constant support and encouragement.

Regards

SURYA KUMAR S (RA2211054040005)

1
 ABSTRACT
A 6-speed gearbox is an advanced transmission system commonly used in modern
vehicles to optimize engine performance, fuel efficiency, and driving experience. By
offering six distinct gear ratios, it allows for finer control over the power delivery
from the engine to the wheels, balancing acceleration and top-speed capabilities.
Lower gears (1-3) provide high torque for efficient acceleration and low-speed
driving, while higher gears (4-6), including a top "overdrive" gear, enable smoother,
fuel-efficient cruising at high speeds by reducing engine RPM. This design reduces
fuel consumption, lowers engine stress, and enhances the vehicle's performance
across varied driving conditions, making the 6-speed gearbox a versatile and efficient
option for contemporary vehicles.

Material selection for a 6-speed gearbox is critical to ensure durability, efficiency, and
optimal performance under varying loads and temperatures. Key materials typically
include high-strength alloys such as hardened steel for gears, which provide wear
resistance and longevity, and lightweight aluminum or magnesium alloys for the
gearbox casing to reduce weight while maintaining structural integrity. Advanced
materials like carbon composites or specialty coatings may also be used to reduce
friction and improve efficiency, ensuring the gearbox can handle high torque and
speed demands while minimizing wear and maximizing fuel economy.
 TABLE OF CONTENTS

6 Speed Gearbox:…........................................................................................1
I. INTRODUCTION
II. TYPES OF GEARBOX
III. OVERVIEW AND PRINCIPLES OF COMPONENTS USED

Design and Associated Calculations...............................................................3

Selection of Bearing ......................................................................................6

Checking For Bending Stress
Checking For Surface Stress

Computer Aided Design….............................................................................7

Conclusion…..................................................................................................8
 Helical Gear: An Introduction

Definition:
A helical gear is a cylindrical gear with teeth cut at an angle to the gear’s axis of
rotation, forming a helix shape. This angled orientation of the teeth allows helical gears
to engage with one another gradually rather than all at once.

Advantages over Spur Gear:

1. Smoother Operation: Due to gradual engagement of the angled teeth,
helical gears experience less vibration and noise, leading to quieter and
smoother operation.
2. Higher Load Capacity: Helical gears can distribute loads over multiple teeth
simultaneously, allowing them to handle higher loads and transmit more
power than spur gears of similar size.
3. Higher Operating Speeds: Helical gears can function effectively at higher
speeds due to their reduced noise and vibration, which makes them suitable for
high-speed applications.
4. Axial Thrust: While this can be a drawback, the axial thrust in helical gears can
sometimes be utilized for specific applications that benefit from additional
axial force on the shafts.
5. Versatile Shaft Configurations: Helical gears can work with both parallel
and non-parallel (crossed) shaft configurations, offering greater design
flexibility than spur gears, which are typically limited to parallel shafts.

General use cases:

1. Systems where smoother and quieter operations are required.
2. Systems where greater power transmission is required without
increasing the size of the gear..
3. Systems where high speed transmission is present. Helical gears are
optimal at higher speeds
4. Systems where design flexibility is required. Helical gears can transmit
between parallel and non parallel shafts
5. Systems which require continuous load distribution. Helical gears can handle
dynamic and variable load effectively by distributing them across multiple
teeth.

1
Industrial application:

Fig 1: Helical gear used in gearbox

1. Automotive Transmissions: For smooth power transmission and to handle

high torque and speed requirements.
2. Gearboxes: In industrial gearboxes for machinery like conveyors, crushers,
and mixers, where efficient and quiet operation is critical.
3. Machine Tools: Used in CNC machines and other precision machinery
for transmitting motion between shafts at varying angles or parallel shafts.
4. Pumps and Compressors: In fluid handling systems, where consistent
torque transmission is required to maintain smooth operation.
5. Elevators: Helical gears are often used in elevator drive systems due to
their ability to handle heavy loads and maintain smooth, quiet movement.
6. Wind Turbines: To transmit power from the rotor to the generator, often
in high-speed and high-torque environments.
7. Railroad Equipment: In locomotives and other heavy machinery, where
high load capacity and smooth operation are crucial.
8. Construction Equipment: Used in cranes, excavators, and other
machinery requiring heavy-duty gearing with smooth and efficient
operation.

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 Helical Gear: Design Calculation

Design of Helical Gear:

A Helical Gear is to be designed for the following data.
Power: 1 Kw
Speed of pinion: 1400 rpm
Speed reduction: 3
Pressure angle: 20°
Helix angle: 45°
Life: 10,000 hours

1. Material Selection:
- Assuming both the pinion and the wheel to be of same material
- Selecting Alloy steel with hardened heat treatment 40 Cr Mo 28
- σu = 70-85 kgf/mm2, Taking it as 80 kgf/mm2
- HRC = 55 to 63, taken as 60
- Cr = 280
- Surface Hardness > 350
BHN Core Hardness < 350
BHN

2. Calculation of Life cycles:

- N = 10,000 hours
N = 10,000 x 60 x RPM
= 10,000 x 60 x 1400
= 84 x 107

3. Calculation of Equivalent Young’s Modulus:

- Eeq of steel is 2.15 x 106 kgf/cm2
- This goes for both the pinion and the wheel as they are of the
same materials

4. Calculation of Design Bending stress:

- σb = 1.4𝐾𝑏𝑙(σ−1)
𝑛𝐾σ
- Here, the values are obtained from page 8.14 of the Design Data Book
- Kbl for steel is found out to be 1
- F.O.S (n) is taken as 2
- Fillet Stress Concentration Kσ is found out to be 1.5
- σ-1 = (0.35σu + 1200) [For the requirements]
- = 4000 kgf/cm2
σb = 1.4 𝑋 1 𝑋
4000
-
2 𝑋 1.5
- = 1866.66 kgf/cm2

5. Calculation of Design Crushing Stress:

- σc = Cr x HRC X Kcl
- Here, the values are obtained from page 8.14 of the Design Data Book
- σc = 280 x 60 X 0.585
- = 9828 kgf/cm2
3
6. Calculation of Design Twisting Moment:
- Mt = Mt.Kd.K
- The Initial Kd.K value is assumed to be 1.3
𝑃𝑜𝑤𝑒𝑟 𝑡𝑜 𝑏𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑 (𝑘𝑤)
- The Initial tM = 97420𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛𝑠(𝑟𝑝𝑚)
1
140
- = 92420
0
- = 69.58 kgf-cm
- Mt = 69.58 x 1.3
- = 90.454 kgf-cm

7. Calculation of approximate center distance:

0.7 )2
a ≥ (i ± 1) 3 𝐸[𝑀𝑡]
- ( σ𝑐 𝑖ψ
- For open type gearing,ψ = 0.3 & i (speed ratio) = 3

3 90.454
6

( 9828
0.7 2 2.15 𝑋 10 𝑋
- a ≥ (3 ± 1)
3𝑋
) 0.3
- a ≥ (3 + 1) (1.03108)
- a = 4.124 cm
- The center distance should be taken in R10 series
- a = 40 mm

8. Calculation of Z1 and Z2:

- Assuming Z1 as 10 teeth
- Z2 = Z1 x i
- = 30 teeth

9. Calculation of Normal Module (mn):

- mn =2 𝑋 𝑎 𝑋 𝑐𝑜𝑠β
𝑍1 + 𝑍2
2 𝑋 40 𝑋
= 𝑐𝑜𝑠45
10 + 30
-
- = 1.414
- Taking Module From Recommended Values (8.2)
- mn = 1.5

10. Recalculation of center distance:

𝑚𝑛 𝑧1 + 𝑧2
- a= 𝑐𝑜𝑠β 2
1.5 10 + 30
- = 𝑐𝑜𝑠45 2
- a = 57.107 mm
- a = 63 mm [Nearest R10 Value]

- ψ 𝑎𝑏
11. Calculation of face width:

- b=ψ xa
=
- = 0.3 x 63
- b = 18.9 mm

4
12. Calculation of Pitch Line Velocity:
π 𝑋 𝑑1 𝑋 𝑛
- v= 6
0
- Here d1 is the pitch circle diameter
- d = 𝑚𝑛 x z
1 𝑐𝑜𝑠β 1

1.5
𝑐𝑜𝑠45
- = x 10
- = 28.554 mm
π 𝑋 28.554𝑋 1400
- v= 6
0
- v = 2.093 m/s
- Selecting Gear based on pitch line velocity
- Selecting IS quality as medium
- Preferred Quality is 8

13. To find Constants Kd and K:

- To Determine the value k from the table (8.15) we need ψ

- k = load concentration factor

- ψ = 𝑏 = 18.9 = 0.6 (aprox.)

𝑑 28.554
- k = 1.03
- kd = 1.3 for the particular pitch line velocity and IS quality (8.16)

14. Recalculating the Design Twisting Moment:

- Mt = Mt x Kd x K
= 90.454 x 1.3 x 1.03
= 121.11 kgf-cm

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 Helical Gear: Design Verification

Checking For Bending Stress:

𝑖±1
- σ = 0.7 [M ]
b 𝑎 𝑋 𝑏 𝑋 𝑚𝑛 𝑋 𝑦𝑣 t

3+1
6.3 𝑋 1.89 𝑋 0.15 𝑋 𝑦𝑣
- = 0.7 [121.11]
- Here yv = form factor = 0.3955
3+1
- = 0.7 6.3 𝑋 1.89 𝑋 0.15 𝑋 0.3955
[121.11]
- = 480.06 kgf/cm2 < σb
- Therefore, The Design is satisfactory

Fig 2: Pictorial Representation of Bending Stress

Checking For Contact Stress:

𝑖±1
𝑖±1 𝑖
- σb
= 0.7 𝑏

3+1
�
6
<2.σc 15 𝑋 10 [
- = 0.7
3+1
�

6. 3𝑋
3 121. 11]
1.89
2
- = 6023.725 kgf/cm
- Therefore, The Design is satisfactory

Fig 3: Pictorial Representation of Compressive Stress

6
 Helical Gear: CAD Modelling and 3D PRINTING

Software Used:
- FreeCAD version 0.21.2

Material used:
- PLA 1.75mm Light Gray filament

Modelling Producere:
- Create an involute Gear for the specifications calculated
- Create a helix of the helix angle and required pitch
- Sweep cut the helix on the gear in order to obtain the required helical gear
- The Model is then exported as .STL file in order to be printed

Fig 3: Final Model of the helical Gear

Fig 4: Final Product

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 Helical Gear: Conclusion

The present report has examined the design principles and the analysis of helical gears with
emphasis placed on the factors that influence the performance, durability and functionality of the
gears in due course of industrial applications. One of the standout benefits of helical gears is that
they perform better than any other types in applications where quietness, flexibility in shaft angles
and high load capacity are desirable. From the analysis of the aforementioned parameters that is,
helix angle, module, pressure angle and material used, improper design and optimization of these
factors are confirmed to be the reason behind the failure of performance and lifespan of the gears
in the operational environment.

The report also emphasized the fact that due to the load distribution on the teeth of helical gears,
the load per tooth of a single tooth is reduced allowing higher load and speed to be kept without
the parts working inefficient. However, the design features which include acceptable axial thrust,
heat, and manufacturing methods are of great importance since they have an effect on the overall
performance and may need other elements, which include bearings or lubrication systems, to be
used in order to achieve best performances.

To sum up, helical gears together with their variations are very widely used in modern mechanics.
They provide high reliability as well as versatility in various industrial applications. Further
improvements in material of the gear and manufacturing and analytical techniques will also make
improvements