DESIGN & FABRICATION OF TWO SPEED VARIABLE TRANSMISSION GEARBOX A PROJECT REPORT Submitted by G.ARAVIND (312313114021) S.ARUN MOZHI THEVAN (3123131140) In partial fulfilment for the award of the degree Of BACHELOR OF ENGINEERING IN MECHANICAL ENGINEERING St. JOSEPH'S COLLEGE OF ENGINEERING 1
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DESIGN & FABRICATION OF TWO SPEED VARIABLE
TRANSMISSION GEARBOX
A PROJECT REPORT
Submitted by
G.ARAVIND (312313114021)
S.ARUN MOZHI THEVAN (3123131140)
In partial fulfilment for the award of the degree
Of
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
St. JOSEPH'S COLLEGE OF ENGINEERING
CHENNAI 600 119
1
ANNA UNIVERSITY: CHENNAI 600 025
APRIL 2016
BONAFIDE CERTIFICATE
DEPARTMENT OF MECHANICAL ENGINEERING
Certified that this project report “DESIGN AND FABRICATION OF TWO SPEED
VARIABLE TRANSMISSION GEARBOX” is the bonafide work of “G.ARAVIND
(312313114021) & S.ARUN MOZHI THEVAN (3123131140)” who carried out
the project work under my supervision.
SIGNATURE SIGNATURE
Dr S.ARIVAZHAGAN M.E. Ph.D., Mr.M.MUNINATHA KOTA M.E
HEAD OF DEPARTMENT ASSISTANT PROFESSOR
Department of Mechanical Engineering, Department of Mechanical Engineering,
St. Joseph’s College of Engineering., St. Joseph’s College of Engineering,
Jeppiaar Nagar, Jeppiaar Nagar,
Chennai-600119 Chennai-600119.
Submitted for project viva-Voice held on ________________
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CERTIFICATE OF EVALUATION
COLLEGE NAME: ST JOSEPH’S COLLEGE OF ENGINEERING
BRANCH: MECHANICAL ENGINEERING
SEMESTER: VI
S. No. Name of the Students who have
done the project Title of the Project
Name of the
Supervisor with
designation
1
2
G.ARAVIND
S.ARUNMOZHITHEVAN
DESIGN AND
FABRICATION
OF TWO SPEED
VARIABLE
TRANSMISSION
GEARBOX
MR.M.MUNINATHA
KOTA M.E
ASSISTANT
PROFESSOR
Department of Mechanical
Engineering.
This report of project work submitted by the above students in partial
fulfilment for the award of Bachelor of Mechanical Engineering Degree in Anna
University were evaluated and conformed to be reports of the work done by the
above students and then evaluated.
Submitted for UNIVERSITY VIVA EXAMINATION held on …………………
INTERNAL EXAMINER EXTERNAL EXAMINER
3
ACKNOWLEDGEMENTS
We would like to express our sincere thanks and gratitude to our college
Chairman Col Dr THIRU JEPPIAAR M.A., B.L., Ph.D., Managing Director Dr
BABU MANOHARAN M.A, BL, Ph.D. Director Mr JAIKUMAR
CHRISTHURAJAN B.E, M.B.A.
Principal Dr VADDI SESHAGIRI RAO M.E., Ph.D., F.I.E. for giving us this
opportunity to carry out this project.
We extend our thanks to the Head of the Department of Mechanical
Engineering, Dr S.ARIVAZHAGAN M.E., Ph.D., for his valuable support and
cooperation.
We also thank MR.M.MUNINATHAN KOTA M.E, Lecturer-Department
of Mechanical Engineering for his guidance and timely suggestions which helped us
to complete this project.
Finally, Mr BALAMURUGAN M.E,Ph.d of Mechanical Engineering for
his constant support and guidance throughout the process of the project.
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TABLE OF CONTENTS
TITLE PAGE NO
Abstract 7
1 Introduction 8
2 Literature review 9
3 Description of equipment 11
3.1 Gearbox 11
3.2 Spur gears 11
3.3 Shafts 15
3.4 D.C motor 17
4 Design and drawing 18
4.1 Calculation for gears 19
4.2 Drawing of sliding mesh gearbox 20
4.3 3D Modeling 21
5 Working principle 22
6 Merits & demerits 23
7 Applications 24
8 Material Considerations 24
9 Conclusion 27
10 Bibliography 28
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LIST OF FIGURES1. Figure 1 11
2. Figure 2 16
3. Figure 3 20
4. Figure 4 22
5. figure 5 17
LIST OF TABLES1 Table 1 25
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ABSTRACT
Conventional gearboxes are capable of varying a given input speed. It is
achieved by meshing of gears in various gear ratios. The torque values are different
during different gear ratios. Hybrid gearboxes are capable of transmitting various
torque levels at the same gear ratio. They have a high torque producing capacity
compared to a conventional gearbox. These gearboxes have provisions for several
inputs and several outputs, unlike one input and one output of a conventional
gearbox. It allows the choice of varied speeds to the inputs.
These gearboxes can be used in a lot of practical applications. As they have
very high loading capacities, they can be used in off-road, commercial vehicles,
military vehicles and other specialty vehicles. They can also be used in cranes,
pumps, tractors, lawn mowers etc. Its most important application is that it can be
used in a hybrid car.
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CHAPTER I
INTRODUCTION
The main objective of our project is to create a gearbox with several inputs and
a single output. For this purpose, we have selected two input shafts and one output
shaft. It is a two speed sliding mesh gear box, controlled by a dog clutch for the
required sliding mechanism. It is simple, effective and a cost efficient design.
It is a hand feed gearbox. Adequate provisions have been given to adapt a
motor or an engine to it. It is designed with utter care to withstand high loading and
has a high factor of safety. The gearbox was fabricated with high accuracy milling
machines and tools with good engineering practices.
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CHAPTER II
LITERATURE REVIEW
TRANSMISSION An assembly of parts including the speed-changing gears and the propeller
shaft by which the power is transmitted from an engine to a live axle. Often
transmission refers simply to the gearbox that uses gears and gear trains to
provide speed and torque conversions from a rotating power source to another
device.
The most common use is in motor vehicles, where the transmission adapts the
output of the internal combustion engine to the drive wheels. Such engines need to
operate at a relatively high rotational speed, which is inappropriate for starting,
stopping, and slower travel. The transmission reduces the higher engine speed to the
slower wheel speed, increasing torque in the process. Transmissions are also used on
pedal bicycles, fixed machines, and where different rotational speeds and torques are
adapted.
Often, a transmission has multiple gear ratios (or simply "gears"), with the
ability to switch between them as speed varies. This switching may be done manually
(by the operator), or automatically. Directional (forward and reverse) control may
also be provided. Single ratio transmissions also exist, which simply change the
speed and torque (and sometimes direction) of motor output.
In motor vehicles, the transmission generally is connected to the
engine crankshaft via a flywheel and/or clutch and/or fluid coupling, partly because
internal combustion engines cannot run below a particular speed. The output of the
transmission is transmitted via driveshaft to one or more differentials, which in turn,
drive the wheels. While a differential may also provide gear reduction, its primary