Constant mesh manual

transmission gear box

 Chapter one
introduction
1.1 BACKGROUND OF THE STUDY

• French inventors Louis-Rene Panhard and Emile Levassor are credited with the
development of the first modern manual transmission. They demonstrated
their three- speed transmission in 1894 and the basic design is still the starting
point for most contemporary manual transmissions.
• These transmissions are called sliding mesh transmissions or sometimes crash
boxes, because of the difficulty in changing gears and the loud grinding sound
that often accompanied.
• Newer manual transmissions on 4+-wheeled vehicles have all gears mesh at all
times and are referred to as constant-mesh transmissions, with "synchro-
mesh" being a further refinement of the constant mesh principle.

2
 1.2 statement of the problem

• We have seen that sliding mesh gears are typically engaged by sliding them on
their shafts,
• which required careful timing and throttle manipulation when shifting, and
• has difficulty in changing gears and the loud grinding sound that often
accompanied,
• because of the above reasons we decided to design constant mesh gearbox.
• In this country there is shortage of car spare parts since they are not
manufactured in the country.

3
 1.3 Objectives

1.3.1 general objective 1.3.2 specific objectives

• The general objective of this project  The specific objectives of this
is to design a constant mesh manual project are:
transmission gearbox. • designing of Gear
• designing of Shaft
• selection of proper way of lubricant
• selection of bearings

4
 1.4 scope and limitation of the project

 The scope of this project is designing of a constant mesh manual transmission

gearbox starting from
• the proper way of material selection,
• force analysis,
• stress analysis,
• determination of gear parameters(like:- adenedum, dedenum, pitch circle, base
circle, outer diameter, face width),
• moment on each shaft(i.e input, main, counter and idler shafts),
• key design,
• proper way of bearing selection,
• result and discussion of the whole material design,
• cost analysis up to the assembly modeling.

5
 limitation of the project

• The project only deals up to the designing of a constant mesh gearbox, but not
manufacturing of it and this is considered as a limitation on this project. Also
while we design our project internet connection was one problem. There is no
brief and clear guidance book which shows material selection with its proper
evidence.

6
 1.5 significance of the project

•The significance of constant gear mesh is the utilization of helical gears. The
double helical gears and the helical gears are extremely beneficial owing to their
quieter operating capabilities. The teeth belonging to the wheels remain intact.
The other gear boxes are noisy and create unwanted din. In this country there is
shortage of car spare parts since they are not manufactured in the country. We
believe our design will figure out this problem.
•It is very evident that the world today is full of vehicles and relies on this mode of
transport. The availability of such mechanisms like constant mesh gearbox which
creates less noise and are cost effective is a fundamental for the people.

7
 Chapter two
literature review

• Main components of constant mesh gearbox:

– Shaft
– Gears
– Key
– Bearing
– Dog clutches
– Housing and lubrication

8
 Engineer Faisel Islam, April 22 2016, “what are important
properties of material for gear application”

 The gear material should have the following properties

• High fatigue strength
• High tensile strength
• Low coefficient of friction
• Good manufacturability
The most common materials used for manufacturing metallic gears are cast iron,
steel, brass and bronze.
 The characteristics that will be used for evaluating the materials are:
• Elastic limit
• Density
• Hardness
• Fatigue strength
• Fracture toughness

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• Table 1: material mechanical properties
Properties Elastic Density Hardness Fatigue Fracture
Limit Strength Toughness
Ductile cast 23.9 440 115 26.1 20
iron
Alloy steel 85 487 140 36 12.7
Medium 44.2 487 120 33.2 10.9
carbon
steel
Aluminum 43.5 156 12 3.13 20
alloy
• Table 2: Material Environmental Aspect

Material and Cost Embodied CO2 foot print Recyclability

properties energy
Ductile Cast 0.318 1.95e3 1.7 Yes
Iron
Alloy Steel 0.254 3.11e3 1.93 Yes
Medium 0.272 2.72e3 1.72 Yes
Carbon Steel
Aluminum 1.07 2.15e4 12.2 Yes
Alloy
10
 Essays, UK. (November 2018). Material Selection For Drive
Shaft Engineering Essay
Compared three materials for the shaft
• Aluminum alloy
• Stainless steel
• Carbon steel
 Table 3: property of aluminum alloy Grade 6061 – T6

ISO standard AA 6061 – T6

Tensile Yield strength (Mpa) 310
Shear Strength (Mpa) 190
Proof Stress (Mpa) 270
Elongation over 50mm (%) 12
Hardness Vickers (HV) 100
Density (kg/m3) 2700
Thermal Conductivity (W/mk) 166
Melting point (0c) 650
Electrical Resistivity 0.040

11
 Table 4: property for stainless steel Grade 304
ISO standard BS 970 Grade 304
Tensile Yield strength (Mpa) 520 – 720
Compressive Strength (Mpa) 210
Proof Stress (Mpa) 210
Elongation over 50mm (%) 45
Modulus of Elasticity (Gpa) 193
Density (kg/m3) 7780
Thermal Conductivity (W/mk) 16.2
Melting point (0c) 1450
Electrical Resistivity 0.072
 Table 5 : Property for Medium Carbon Steel Grade 080M30

ISO standard BS970 080M30

Tensile Yield strength (Mpa) 550
Ultimate Tensile Strength (Mpa) 930
Hardness (HB) 269
Elongation over 50mm (%) 16
Young’s Modulus (Gpa) 205
Density (kg/m3) 7820
Thermal Conductivity (W/mk) 46.6
Specific heat capacity (J/g-0c) 0.475
Electrical Resistivity 234
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• Table 6: Comparison between three selected materials

ISO Tensile Elongatio Density Thermal Electrical Price per

standard Yield n over (kg/m3) Conductiv Resistivit ton (USD)
strength 50mm ity y
(Mpa) (%) (W/mk)
Aluminu 310 12 2700 166 0.040 2220
m Alloy
AA 6061-
T6
 
Stainless 520-720 45 7780 16.2 0.072 4450
steel BS
970
Grade
304
 
Carbon 550 16 7820 46.6 234 740
steel
BS970
080M30

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 “Bearing (Mechanical)”, 4 November 2019, Wikipedia
 The basic criteria to select bearing type are
• Loads
• Speed and friction
• Misalignment
• Temperature
• Precision
• Stiffness
• Mounting and dismounting
• Cost and availability
 Rolling element bearing brings place balls or rollers between two rings or
races that allows motion with little rolling resistance and sliding. The springs
include ball bearings and roller bearings. Ball bearings are the most common
type of rolling element bearing. These bearings can handle both radial and
thrust loads. Roller bearings are able handle a much heavier radial loads
because they do not use balls instead they have cylinders allowing more
contact between the races.

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Ludwig, L., May-June 2004, “Properties of Enclosed Gear Drive
Lubricants.”, Machinery Lubrication

 The most Factors affecting lubricant selection are

• Bearing speed
• Bearing size
• Type of bearing
• Load
• Lowest and highest temperature
• Torque
• Viscosity

 Comparison of 3 types of gear lubricant

• R & O lubricants
• Antiscuff gear lubricant
• Compounded gear lubricants

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 R&O Gear Lubricants
• Rust and oxidation inhibited (R&O) gear lubricants do not contain antiscuff
additives or lubricity agents. R&O gear oils generally perform well in the
categories of chemical stability, demulsibility, corrosion prevention and foam
suppression. These products were designed for use in gearing operating under
relatively high speeds, low loads, and with uniform loading (no shock loading).
 Antiscuff (Extreme Pressure) Gear Lubricants
• Antiscuff gear lubricants, commonly referred to as extreme pressure (EP)
lubricants, have some performance capabilities that exceed those for R&O oils.
In addition to the properties listed for R&O lubricants, antiscuff lubricants
contain special additives that enhance their film strength or load-carrying
ability.
 Compounded Gear Lubricants
• The compounded gear lubricant is the third type of common lubricant. In
general, a compounded lubricant is mixed with a synthetic fatty acid
(sometimes referred to as fat) to increase its lubricity and film strength.
Because of sliding contact and the negative effects of EP agents, compounded
lubricants are generally the best choice for these applications.

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 Summary of Literature Review

• Based on the above literature we reviewed, it is clear that alloy steel is the best
material for the gear because it has highest value of elastic limit, hardness and
fatigue loading. Along with this it has moderate value of environmental aspect
and lowest cost of material. For the drive shaft, Aluminum Alloy is chosen. The
reason for the selection of Aluminum Alloy is production by extrusion, has
good mechanical properties and exhibits good weld ability. Roller bearings are
able handle a much heavier radial loads because they do not use balls instead
they have cylinders allowing more contact between the races. Due to the above
reasons we have select rolling bearing element (especially roller bearing). We
have select compounded gear lubricants based on the above definition.
Specifically, we decided to use oil as a lubricant for the gears and grease as a
lubricant for the bearings.

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 Chapter three
Geometric analysis

The given parameters for this design of gearbox are the following:
Manual gearbox specifications
Product: Manual transmission gearbox
Gear Ratio:
Four speed box
Top 1
3rd 1.3
2nd 2.1
1st 3.4
Reverse 3.5

Drive Torque: 230Nm@1600-2000rpm

Type: Constant Mesh

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 Methodology

Number of
teeth

pitch diameter

Gear face width

Torque &
Dog clutch
Velocity
Radial
Force Analysis

Tangential

Geometric
Main shaft
Analysis

Lay shaft
Bending
Moment
Analysis
Shaft Input shaft
Design of
diameter
Idler shaft
Key Muff coupling

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 Design of Gears

•  

• Input shaft power: from input torque and speed

• The number of teeth and speed of each gear

• From specification driving speed [1600-2000rpm] therefore, let’s take in between
for the speed of counter shaft {NC= }=1800rpm.This speed is constant throughout
the counter shaft since the gears are mounted in fixed. And gear ratio for gear to
pinion (G) given as;
• G= TDRIVEN/TDRIVER =NDRIVER/NDRIVEN=2000RPM/1800RPM =1.11
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Cont.
1st Gear ratio꞉
•  
• Gear ratio (G.R) =

• But NB=ND= NH=NJ=1800rpm……… (On the same shaft)

• G1= ===588.24rpm
• We know that the distance between the two shafts (main shafts lay shafts is
constant then.)
• TA+TB=TC+TD=TE+TF=TG+TH=TI+TJ+TK
• TA+TB =TG+TH …………………………………………………. Eq(1)
• NB=ND=NF= NH=NJ=1800RPM ……………………………… Eq(2)
• G1=3.4………..but from G==1.11TB=1.11TA………………………Eq (3)
• TB=1.11TA =1.11*30=33……..since, assume TA=30
• G1=3.41.11*=3.4=3.06TG=3.06TH……………………..Eq (4)
• By Substitute Equation (3) and (4) into Equation (1)
• TA+TB =TG+TH30+33=3.06* TH+ THTH=15
• Then from Equation (1) TA+TB-TH =TGTG =63-15 =48
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Cont.

2nd gear ratio꞉

•  
• G2===2.1 ……………………Equation (1) but, NF=NB=1800rpm
•  G2= ===952.4rpm
• ,and =1.11
• = G21.11*=2.1TE=1.89* TF ……….Equation (2)
• TA+TB=63=TE+TF…… Equation (3)
• By substitute the values of TA, TB& TE
• TF=63-TE=TF=63-1.89TF TF=22 and  TE=63-22=41
3rd gear ratio꞉
• G3===1.3…………………… Equation (1) but, ND=NB
•  G3= ===1538.5rpm
• 1.11*= 1.3 TC=1.17* TD …………………..Equation (2)
• TA+TB =TC+TD………………………….…… Equation (3)
• We substitute the values of TA, TB & TC
• TD=TA+TB –TC=63-1.17* TD TD=29 and  TC=1.17*29=34
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Cont.

•  
Top gear: running speed (NA)=2000 rpm
Reverse gear꞉
• Gr= =3.5= =3.5…………………… Equation (R1)
• = =3.5 and =3.5NI===571.4rpm
• =3.51.11=3.5 TI=TJ*3.15……….…… Equation (R2)
• TA+TB =TK+TI+ TJ………………………..……… Equation (R3)
• Assuming that the idle gear teeth is TK = 14
• Substitute the values of TA, TB & TK from Equation (R2) into Equation (R3)
• =3.5  TI =3.15TJ
• TA+TB =TK+TI+ TJ 63=14+3.15TJ+TJ
• TJ=15, TI =3.15*TJ  TI=47
• =  NK = == 1928.8rpm

• Torque :- p=Tiωi=Toωo , To= Ti

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Cont.

•  

• The other parameters are calculated as follows

• Assuming module (m) = 5
• Pitch circle diameter=D=mT
• Circular pitch =P=*m=*5=15.7
• Normal pitch (Pn): = P *cos ψ=15.7*cos30=13.6mm/teeth
• Addendum(A) = 0.8*m= 0.8* 5=4mm
• Dedendum(Dd) = m =5mm
• Minimum total depth = 1.8*m=1.8*5=9mm
• Minimum clearance = 0.2*m=1mm
• Thickness of tooth = 1.5708*m=1.5708*5=7.854mm.
• Face width(b):-
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Cont.

•
• Peripheral
  velocity for all gear , Vi =Vo =

25
 Design of Shaft

•  

• All the parameters nedded for the shaft design are calculated by using the following
equations :
• ΣFy = 0
• ΣMo=0
• Resultant bending moment
• RM=

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 Chapter four
result and discussion

Gear No of teeth Pitch Torque (N) (N) Velocity

diameter (Nm) (m/s)
(mm)

A 30 150 230 3004.5 1093.5 1734.6 15.7

B 33 165 255.5 3004.5 1093.5 1734.6 15.7
C 34 170 299 3443.13 1253.2 1987.89 13.7
D 29 145 255.5 3443.13 1253.2 1987.89 13.7
E 41 205 483 4615.16 1679.9 2664.79 10.22
F 22 110 255.5 4615.56 1679.9 2664.79 10.22
G 48 240 782 6681.44 2431.8 3857.53 7.06
H 15 75 255.5 6681.44 2431.8 3857.53 7.06
I 47 235 805 6681.44 2431.8 3857.53 7.06
J 15 75 255.5 6681.44 2431.8 3857.53 7.06
K 14 70 238 6681.44 2431.8 3857.53 7.06
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Cont.
• The previous table shows the relation between the numbers of teeth, pitch diameter,
Torque, tangential, radial, and axial loads and peripheral velocities of each gear.
The maximum Torque is developed in gear “G” which is the first gear and the
maximum speed is developed on gear “A” which is the top gear. We calculate stress
developed on each gear is less than that of the allowable stress which is 172Mpa.
When the diameter of the driven gear increases the torque of the driven gear also
increases, but if the diameter of the driven gear decreases relative to the driver gear
then the speed of the driven gear increases while reducing torque.

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Cont.

Shaft Diameter(mm) Length(mm) (N) Torque(Nm)

In put 32 150 3004.5 1093.5 328

Out put 66 600 21421.6 7796.7 3104

Counter 67 840 24426 8890.2 2958.7
Reverse 38 150 6681.44 2431.8 568

• In this design of constant mesh gearbox there are totally four shafts as stated in
the above table and we can see which shaft produces maximum torque and
which shaft produces minimum torque. Based on the above table it is clear that
the main shaft produces a maximum torque and the input shaft produces a
minimum torque.

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 Cost Analysis

•
• To calculate the cost for all component of the gearbox, we have to be calculate the
 mass of the shaft ,gear, bearing and key based on the constant material density
(7500
• The volume of the gear can be calculated by this formula:-
• V=(d2gear-d2shaft) *b
• The volume of shaft can be calculated by:-
•
• The volume of the key can be calculated by:-
•
• The mass can be calculate by;-
• m=ρ*V
• now we can calculate the cost
• Cost =m*birr/Kg = m * 62birr

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Cont.
•   𝑇ℎ𝑒 𝑡𝑜𝑡𝑎𝑙 𝑔𝑒𝑎𝑟 𝑐𝑜𝑠𝑡 = 5692.38𝑏𝑖𝑟𝑟

Let’s assume the production take two days

So labor cost=4000ETB(2*4*60)
So labor cost=4480ETB
Machine cost is the amount of money paid for the machine
Assume the amount of birr paid for the machine is 1500ETB/day
Machine cost =*2day
Machine cost=3000ETB

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 Chapter five
conclusion and recommendation

 CONCLUSION
• In this design project, we discussed about manual transmission system
especially constant mesh gearbox. We have designed and calculated the
fundamentals parts of the gears, shafts, keys, bearings and lubrication needed
for them is discussed and analyzed. From our design especially on the design of
gears we have got developed stress at each gear which is less than of our
material allowable stress which is 172N/mm2. Due to this we conclude that
our design project is safe.
 RECOMMENDATION
• Finally, we would like to suggest the extension of this project in detail and
further analysis can be made in software to know the most vulnerable parts of
the design.

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 References

1. ^ R.S khurmi and J.K Gubta (2005). A textbook of machine design (14th ed)
2. ^ “Manual Transmission”, October 25 2019, Wikipedia
3. ^ “Full notes on constant mesh gearbox”, June 8 2017, mech4stuy
4. ^ Engineer Faisel Islam, April 22 2016, “what are important properties of
material for gear application”, www.quora.com
5. ^ Essays, UK. (November 2018). Material Selection For Drive Shaft Engineering
Essay. Retrieved from
https://www.ukessays.com/essays/engineering/material-selection-for-drive-sh
aft-engineering-essay.php?vref=1
6. ^ Mechanical Engineer S.K Mani, August 31 2019, “what is suitable material for a
transmission shaft, and why?” www.quora.com
7. ^ “Bearing (Mechanical)”, 4 November 2019, Wikipedia
8. ^ “6 most popular types of mechanical bearings”, CRAFTECH INDUSTRIES
(craftechin), 2019
9. ^ Karim Nice, "How Bearings Work", 11 October 2000, HowStuffWorks.com
10. ^ Ludwig, L., May-June 2004, “Properties of Enclosed Gear Drive Lubricants.”,
Machinery Lubrication
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