FABRICATION OF BUTTON OPERATED GEAR SHIFTING

MECHANISM

PROJECT REPORT 2019-2020

SUBMITTED BY

NAME REG.NO

S.SELVAKUMAR 18219884

G.SELVAMANIKANDAN 18219885

P.SIVAVISHNU 18219889

A.SURESH 18219907
18219925
N.VIGNESH

UNDER THE GUIDANCE OF

Mr. S. PRAKASH,
LECTURER
In partial fulfillment of the requirements of the award of
DIPLOMA IN MECHANICAL ENGINEERING
Of the directorate of technical education
Government of Tamil Nadu
DEPARTMENT OF MECHANICAL ENGINEERING
P.A.POLYTECHNIC COLEGE
Pollachi-642002
 P.A.POLYTECHNIC COLLEGE
Pollachi-642002

Department of Mechanical Engineering

CERTIFICATE
Name : _________________________________

Register number : _________________________________

This is to certify that the project work entitled

FABRICATION OF BUTTON OPERATED GEAR SHIFTING

MECHANISM

Is a bonafide work done by

in partial fulfillment of the requirement for the award of

DIPLOMA IN MECHANICAL ENGINEERING

During the year 2019-2020

Faculty guide Head of the department

Submitted for the practical examination held on________________

Internal examiner External examiner

ACKNOWLEDGEMENT
 ACKNOWLEDGEMENT

First and foremost, we pay our sincere and honorable salutation to the
almighty for equipping us with all the strength and courage throughout our
venture in the project.

At this pleasing movement of having successfully completed our project,

we wish to convey our sincere thanks and gratitude to the Chairman,
Dr.P.Appukutty, for this continuous encouragement throughout our endeavor,

We would also like to express our sincere thanks to our beloved CEO,
Dr.T. Manigandan and Principal Mr.A.Ponnambalam, for forwarding us to
do our project and offering adequate duration in completing our project in a
successful manner.

We are also grateful to Mr.N.Senthil Kumar, Head of the department

for his constructive suggestion &encouragement during our project.

We would very much like to convey our heart full thanks to our Guide
Mr.S.Prakash, for the consistent guidance and valuable suggestion given by
him for the successful completion for our project work.

The various suggestion related to our project was collected from various
Staff members of Mechanical Department and this kind of encouragement
from our staff has made this project work as a successful one.

We are also thankful for other teaching and non-teaching staff members of
all other departments. We are much thankful to our family members for
encouragement and helping as throughout the project.
CONTENTS
 CONTENTS

CHAPTER PAGE
TITLE
NO. NO.
1 SYNOPSIS 1

2 INTRODUCTION 2

3 DESCRIPTION OF PART 3

4 FABRICATION 6

5 WORKING PRINCIPLE 7

6 DESIGN AND DRAWING 9

7 APPLICATION AND MERITS 12

8 MATERIAL SELECTION 13

9 BILL OF MATERIAL 16

10 COST ESTIMATION 17

11 CONCLUSION 19

12 BIBLIOGRAPHY 20

13 PHOTOGRAPHY 21
SYNOPSIS
 SYNOPSIS

Our project deals with the FABRICATION OF BUTTON OPERATED

GEAR SHIFTING MECHANISM which is useful for an automobile. The
main objective of this concept, to apply the gear by using automation system in
automobiles. This is an innovative concept mainly used in two wheelers, to
control the vehicle. In this project we can design the pneumatic gear changing
mechanism in two wheeler vehicles by using the pneumatic cylinder. In this
system we can easily control the vehicle.

1
INTRODUCTION
 INTRODUCTION

A gear is a component within a transmission device that transmits

rotational torque by applying a force to the teeth of another gear or device. A
gear is different from a pulley in that a gear is a round wheel that has linkages
("teeth" or "cogs") that mesh with other gear teeth, allowing force to be fully
transferred without slippage. Depending on their construction and arrangement,
geared devices can transmit forces at different speeds, torques, or in a different
direction, from the power source.

An induction motor (IM) is a type of alternating current motor where

power is supplied to the rotating device by means of electromagnetic induction.
It is also called asynchronous motor.

2
DESCRIPTION OF PARTS
 DESCRIPTION OF COMPONENTS

MAJOR PARTS

The major parts “GEAR SHIFTING MECHANISM” are described below:

 Bearing.
 Compressor.
 Pneumatic cylinder.
 Solenoid valve.
 Engine.
BEARING
A bearing is a device to permit constrained relative motion between two

parts,typically rotation or linear movement. Bearings maybe classified broadly

according to the motions they allow and according to the principle of operation.

Low friction bearings are often important for efficiency, to reduce friction by

virtue of its shape, by its material, or by introducing and containing a fluid

between surfaces.

Different types of bearings

 Ball bearings,

 Roller bearings,

 Ball thrust bearings,

 Tapered roller thrust bearings.

3
BALL BEARINGS

Ball bearing is a type of rolling-element bearing that uses balls to

maintain the separation between the bearing races. The purpose of a ball

bearing is to reduce rotational friction and support radial and axial loads. ... As

one of the bearing races rotates it causes the balls to rotate as well.

COMPRESSOR

Compressor is the air producing machine. They collect the airs from the

atmosphere are in the running of machine are engine. Air compressors are

utilized to raise the pressure of a volume of air.

Air compressors are available in many configurations and will operate

over a very wide range of flow rates and pressures.

PNEUMATIC CYLINDER

Pneumatic cylinders impart a force by converting the potential energy of

compressed gas into kinetic energy. This is achieved by the compressed gas

being able to expand, without external energy input, which itself occurs due to

the pressure gradient established by the compressed gas being at a greater

pressure than the atmospheric pressure. This air expansion forces a piston to

move in the desired direction.

4
SOLENOID VALVE

A solenoid valve is an electromechanically operated valve. Solenoid

valves differ in the characteristics of the electric current they use, the strength
of the magnetic field they generate, the mechanism they use to regulate the
fluid, and the type and characteristics of fluid they control.

ENGINE

The engine consists of a fixed cylinder and a moving piston. The

expanding combustion gases push the piston, which in turn rotates the
crankshaft. ... After the piston compresses the fuel-air mixture, the spark ignites
it, causing combustion. The expansion of the combustion gases pushes the
piston during the power stroke.

5
FABRICATION
 FABRICATION

FRAME

It is a base made by a welding process. It is prepared by joining the L shape

metal plates. It is made of mild steel. All parts are fitted in this main frame.

MILD STEEL

Mild steel is also known as plain carbon steel,is the most common form of
steel because it is relatively low while it provides material properties that are
acceptable for many application, more so than iron. Low carbon steel contains
approximately 0.05% - 0.5% carbon make it malleable and ductile.Mild steel
has low tensile strength but it is cheap and easy to form. Surface hardness can
increased by a carbonize method.

In this project we also select this mild steel material for both the frame for
effective price and properties. It is little more corrosive but it can be apply
quality paint coatings and lubrications on the surface of material.

ARC WELDING

Arc welding requires a large current generally of a relative low voltage after
the arc has been struck. The arc is struck between an electrode and the work
piece to the base metal. The electrode may have either a largely non
consumable metallic tip or it may be a consumable rod of carbon or a
consumable metal rod or wire.

6
WORKING PRINCIPLE
 WORKING

Here we have two pneumatic cylinder arrangements which are mounted

on either side of the vehicle pedal rest for applying the gear. The pneumatic
cylinder is fixed at the end of the flat pedal rest. The plate rest is pivoted at the
center. The clutch spring is also operated with help of pneumatic cylinder.
Clutch cable is fixed to the pneumatic cylinder piston rod. Before applying the
gear or reducing the gear the pneumatic cylinder which is connected to the
clutch cable is actuated and the clutch is engaged or disengaged. The solenoids
are operated with the help of electric power supply . One of the solenoid is used
to apply the gear and another one for reducing the gears. Depending up on the
speed and the clutch will engage or disengage.

7
FLOW PROCESS CHART

Cut the material Inspection

required for
frame

solenoid valves
are connected to
Welding the the cylinders.
frame and fix the
wheels

Engine assembly
is mounted on
Inspection
frame.

Assemble the cylinder is

engine attached to the
arrangement gear shaft.
with wheel

8
DESIGN AND DRAWING
9
10
11
APPLICATION AND MERITS
APPLICATION

 It is applicable in all types of two wheeler vehicles.

MERITS

 Automatic method.

 Quick response is achieved.

 Simple in construction.

 Easy to maintain and repair.

 Cost of the unit is less.

 Continuous operation is possible without stopping.

12
MATERIAL SELECTION
 MATERIAL SELECTION

FACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are discussed
below

PROPERTIES

The material selected must possess the necessary properties for the
proposed application. The various requirements to be satisfied can be
strength, surface finish, rigidity, chemical stability, etc…

The following four types of principle properties of materials decisively

affect their selection:

1) Physical

2) Mechanical

3) From manufacturing point of view

4) Chemical

The various physical properties concerned are melting point, thermal

conductivity, specific heat and co-efficient of thermal expansion, specific
gravity, electrical conductivity, magnetic properties etc..

The various mechanical properties concerned are strengthen at various

loads such as tensile, compressive, shear, bending, torsion, impact, dead,
gradual loads, hardness, wear resistance and sliding properties.

13
 The various properties concerned from the manufacturing point of view
are

 Cost ability

 Weld ability

 Bras ability

 Forge ability

 Machine ability

 Surface properties

 Shrinkage

 Deep drawing

MANUFACTURING CASE

Sometimes the demand for lowest possible manufacturing cost or surface

qualities obtainable by the application of suitable coating substances may
demand the use of special materials.

QUALITY REQUIRED

This generally affects the manufacturing process and ultimately the

materials. For example, it would never be desirable to go for casting of a less
number of components which can be fabricated much more economically by
welding or hard forging the steel.

14
AVAILABILITY OF MATERIAL

Some materials may be source or in short supply. It then becomes

obligatory for the designer to use other material which though may not be a
perfect substitute for the material designed. The delivery of materials and
delivery date of product should also be kept in mind.

SPACE CONSIDERATION

Sometimes high strength materials have to be selected because the forces

involved are high and space limitation are there.

COST

As in any other problems, in selection of materials plays an important part

and should not be ignored. Sometimes factors like scrap utilization, appearance
and non-maintenance of the designed part are involved in the selection of
proper materials.

15
BILL OF MATERIAL
 BILL OF MATERIALS

DESCRIPTION OF THE QUANTITY MATERIAL

S.NO
PARTS REQUIRED

1. Engine 1 Standard

2. Soleniod valve 1 Standard

3. Gear shaft 1 Mild steel

4. Bearing arrangement 1 Standard

5. Pneumatic cylinder 2 Standard

6. Frame stand 1 Mild steel

7. wheel 1 Rubber

8. Button 1 Plastic

16
COST ESTIMATION
 COST ESTIMATION

APPROXIMAT TOTAL
DESCRIPTION OF QUANTITY E COST/UNIT COST
S.NO
THE PARTS REQUIRED
Rs Rs

1. Pneumatic cylinder 2 500 1000

2. Solenoid valve 2 700 1400

3. Engine 1 2500 2500

4. Bearing 1 250 250

5. Chain and sprocket 1 500 500

6. Frame stand 1 800 800

7. Wheel 1 400 400

8. Shaft 1 350 350

9. Button 1 300 300

10. Wire 1 200 200

11. Accelaration cable 1 150 150

TOTAL COST 7750

17
LABOUR COST

Drilling, welding, power hacksaw, tool grinding

Cost: RS 1000/-

OVER HEAD COST

The overhead charges are arrived by “Manufacturing cost”

Manufacturing cost =Material cost + labour cost

=7750+1000

=RS 8750/-

Overhead charge =20% of manufacturing cost

=RS 1750/-

TOTAL COST

Total cost =Labour cost +Overhead charge

+Material cost

=1000+1750+7750

=RS 10500/-

Total cost of this project=RS 10500/-

18
CONCLUSION
 CONCLUSION

This project is made with pre planning, that it provides flexibility in

operation.

This innovation has made the more desirable and economical. This
project “GEAR SHIFTING MECHANISM IN AUTOMOBILES” is designed
with the hope that it is very much economical and help full to so many
industries.

This project helped us to know the periodic steps in completing a project

work. Thus we have completed the project successfully.

19
BIBILIOGRAPHY
 BIBILOGRAPHY

1) Design data book - P.S.G.Tech

2) Strength of materials - R.S Kurmi

3) Manufacturing technology - M.Haslehust

4) Design of machine elements - R.S.Kurumi

20
PHOTOGRAPHS
21
22