A

Project Report on
“TYPES OF GEAR BOX”

Submitted by
Shreyash Sanjay Waghamare

Under the guidance of

Prof. D. S. Dhobe

Lecturer in Mechanical Engineering Department

GOVERNMENT POLYTECHNIC, THANE.

(2020-2021)
GOVERNMENT POLYTECHNIC,
THANE.
Phadke Rd, opp. Bharat Gears Ltd, Phadkepada, Mumbra,
Thane, Maharashtra 400612.
 CERTIFICATE

This is to certify that report entitled “Types of Gear Box” Submitted by the
students from final year of diploma in mechanical engineering of this institute has
completed the project work within institute premises and it fulfil the guidelines
prescribed by Maharashtra State Board of Technical Education.

Submitted by:

Shreyash Sanjay Waghamare

Dr. S. D. Dhobe Prof: S. D. SANAP

(Lect. In ME Dept.) (Head of Department)

EXTERNAL EXAMINER Dr. NITIKET N. MHALA

(Principal)
 ACKNOWLEDGMENT

We wish to express our profound gratitude and

intentness towards Prof. D. S. Dhobe in the Mechanical
Engineering, at Government Polytechnic, Thane for
introducing the project of “Types of Gear Box” and for
the inspiring guidance and criticism and valuable
suggestions through the project work.
TYPES OF GEAR

What Is A Gearbox? (Transmission) – Types, Parts, Function

& Diagram

👉 Table of Content 👈

1What Is A Gearbox?
2Introduction
3The Necessity Of Gearbox
4Parts Of Gearbox
5Types Of Gearbox
6Purpose Of Gearbox
7Function Of Gearbox
8Advantages And Disadvantages Of Gearbox
9FAQ

✓ What Is A Gearbox?
The gearbox is a mechanical device used to increase the output torque or to change
the speed (RPM) of a motor. The shaft of the motor is connected to one end of the
gearbox and through the internal configuration of gears of a gearbox, provides a
given output torque and speed determined by the gear ratio.

✓What Is A Gearbox
Gearbox Diagram (What is gearbox in Automobile)
Introduction
High torque is required to start the vehicle from rest, accelerating, hill climbing,
pulling a load and facing other resistances. But the IC engine operates over a
limited effective speed range which produces a comparatively low torque. In such
a situation, the engine is responsible for the stall and the vehicle rests if the speed
falls below the limit.

The torque developed by the engine is increasing within limits with the increase of
engine speed and reaches a maximum value at some predominant speed. If the
engine directly connects to the driving axle, the engine speed may reduce.

Due to the variable nature of the vehicle resistance resulting in load and gradient
changes, it require that the engine power should be available over a wide range of
road speeds. Hence, for this reason, the engine speed maintain by using a reduction
gear resulting in the road wheels rotating at a proper speed suited to the operating
conditions of the vehicle.

Therefore, a single torque multiplication in the rear axle must be interposed and a
variable multiplication factor in the gearbox is provided for this purpose.

The Necessity Of Gearbox

To maintain engine speed on all conditions of load and vehicle speed, the gearbox
uses a system to maintain engine speed, while sacrificing the same road speed. To
enable the engine to run faster onroad wheels as well as to multiply the torque, a
gearbox is required.

Parts Of Gearbox
1. Clutch Shaft / Driving Shaft / Input Shaft
A clutch shaft is a shaft that takes power from the engine to supply another shaft.
The clutch shaft or driving shaft is connected through the clutch and when the
clutch is engaged, the driving shaft also rotates. Only one gear is fixed on the
clutch shaft and this engine rotates with the same speed as the crankshaft. In
addition, the driving shaft and main shaft are in the same line.

The counter shaft is a shaft that connects directly to the clutch shaft. It has gear
which connects it to the clutch shaft as well as the main shaft. It can be run at
engine speed or below engine speed according to gear ratio
. Counter Shaft / Layshaft
 The counter shaft is a shaft that connects directly to the clutch shaft. It has gear
which connects it to the clutch shaft as well as the main shaft. It can be run at
engine speed or below engine speed according to gear ratio.
The main shaft or output shaft that rotates at different speeds and also provides
the necessary torque to the vehicle. The output shaft is a splined shaft, so that the
gear or synchronizer can be moved to engage or disengage.
Main Shaft / Output Shaft
The main shaft or output shaft that rotates at different speeds and also provides
the necessary torque to the vehicle. The output shaft is a splined shaft, so that the
gear or synchronizer can be moved to engage or disengage.

2. Bearings
The bearings are required to support the rotating part and reduce friction. The
gear box has both a counter and main shaft which is supported by the bearing.

3. Gears
Gears are used to transmitting the power from one shaft to another shaft. The
amount of torque transmitted through the gears depends on the number of teeth
and the size of the gears. Higher the gear ratio, higher the torque / acceleration
and lower the speed. All gears except those on the main shaft are fixed to their
respective shafts; They can slide in any of the directions along the shaft.

4. Gear Selector Fork

Gear selectors are simple devices that use a lever that selects gears to engage in
disengage mechanisms. The motion of the lever slides the engaging part on the
shaft. It depends on the type of gearbox whether the lever slides the gear or
synchronizer that are already forged along the main shaft.

Types Of Gearbox
➤ Manual Transmission
 1. Sliding Mesh Gearbox

(I) Sliding Mesh Gearbox

It is the simplest type of gearbox. In this gearbox, spur gears are used. The Figure
shows the construction of a sliding mesh type transmission having three forward
and one reverse speeds. There are three gears (1, 6 and 5) attached on the main
shaft and four gears (2, 3,4 and 7) on the layshaft.

The two gears on the main shaft (6 and 5) can be slided by a shafting yoke and
mesh with the gears (3 and 4) on a layshaft. Therefore, it is called a sliding mesh
gearbox. A separate idler gear (8) is mounted on the idler shaft.
2. Constant Mesh Gearbox
(II) Constant Mesh Gearbox
Figure shows the construction of a constant mesh type gearbox having three
forward and one reverse speeds. In this type of gearbox, all gears are constantly
in mesh and dog clutches are used for engaging and disengaging the gears. The
dog clutches (D) and D2) are mounted on the main shaft. One (D2) is connected
between clutch gear and reverse gear whereas the other (D)) is placed between
low speed gear and reverse gear. The splines are provided on the main shaft for
the linear movement of dogs. Dog clutch can slide on the shaft and rotate along
with it. All gears are rigidly fixed on the counter shaft.
All main shaft and layshaft gears, and idler gears are engaged by dog clutch to
obtain opposite and slow speed. Only reverse gears are spur gear type and all
others are helical gears.
As compared with the sliding mesh type, the constant mesh type gearbox meshes
more readily with the gears having less danger of damaging during meshing
because the gear diameters are smaller with few numbers of teeth. So, this type
has more defects when compared to a synchromesh type. The necessity of double
clutching is needed so that it is not used to any large extent.
 3. Synchromesh Gearbox

(III) Synchromesh Gearbox

Synchromesh gearbox uses synchronizer instead of sliding dog clutches to affect
the ratio change. The synchromesh gearbox is similar to the constant-mesh
gearbox, but the synchromesh gearbox is provided with a synchronizer, the device
by which two gears to be engaged are first brought into frictional contact which
equalizes their speed, afterward they are engaged smoothly.

To engage, when the gear lever is moved the synchronizer cone meets with a
similar cone on the pinion. Due to friction, the rotating pinion is made to rotate at
the same speed as the synchromesh unit. To give a positive drive further,
movement of the gear lever enables the coupling to override several spring load
balls and the coupling engages with the dogs on the side of the pinion.

Since both pinions and synchromesh units are moving at the same speed, this
engagement is done without noise or damage to the dogs. A slight delay is
necessary before engaging the dog teeth so that the cones have a chance to bring
the synchronizer and pinion to the same speed.

➤ Epicyclic Gearbox
What is Gearbox
2. Epicyclic Gearbox
An epicyclic gear train (also known as planetary gear) consists of two gears so that
the center of one gear rotates around the center of the other. A carrier connects
the centers of two gears and rotates to carry one gear, called planet gear or
planet pinion, around the other, called sun gear or sun wheel. The rays of the
planet and the sun form traps so that their pitch circles are rolled without slip. A
point on the pitch circle of the planetary gear traces an epicyclic curve. In this
simplified case, the sun gear is fixed and there is planetary gear rolled around the
sun gear.

An epicyclic gear train can be assembled so the planetary gear is rolled onto a
fixed, external gear ring or inside the pitch circle of the ring gear, sometimes
called the annular gear. In this case, the curve detected by a point on the planet
pitch circle is a hypocycloid.
The combination of epicyclic gear trains with a planet engaging both a sun gear
and a ring gear is called planetary gear train. In this case, the ring gear is usually
fixed and the sun gear is operated.

➤ Automatic Transmission
4. Automatic Transmission
Various speeds are obtained automatically in gearboxes known as automatic
gearboxes. Generally, the driver selects the car condition such as neutral, forward
or reverse. The gear selection, timing, and engagement of gear for the required
gear speed select automatically when the accelerator press or depress.. The
Automatic gearbox does not require a gear change lever and a clutch pedal. Since,
both clutch and transmission are a combined unit which works automatically. The
automatic gearbox operates in two ways namely.1. Hydramatic transmission,
and2. Torque converter transmission Nowadays, automatic transmissions are
popular with various names prescribe by the manufacturers. They may differ in
construction slightly. Somebody employs only fluid coupling with the planetary
transmission. But others may include a torque converter with fluid coupling and
planetary transmission as per their requirements.

1. Hydramatic Transmission
(I) Hydramatic Transmission
In the case of a dramatic transmission gearbox, the planetary gear sets connect in
such a way that power may transmit through them. A centrifugal governor in the
transmission chooses the proper gear according to the speed and throttle
position.

The gear shifting from one gear to another gear is done through hydraulically
operated pistons by actuating springs. These springs control the brake bands on
the planetary gear sets and clutches within the planetary unit. The various shifts
achieves by the throttle and centrifugal governor.

2. Torque Converter Transmission

,(II) Torque Converter Transmission
A torque converter is a type of fluid coupling that transmits rotational power from
a prime mover, such as an internal combustion engine, to a rotating driven load.
In a vehicle with an automatic transmission, the torque converter connects to the
power source to the load. It is usually located between the engine’s flexplate and
transmission. The manual transmission will have an equal space mechanical
clutch.

The main feature of a torque converter is its ability to increase torque when the
output rotational speed is so low that it allows the fluid from the winding vanes of
the turbine to separate from the stator while it close against its one-way clutch,
thus providing the equivalent of a reduction gear.This is a feature beyond simple
fluid coupling, which can match rotational speed, but does not multiply torque,
thus reducing power.
Torque converter transmission system employs fluid coupling, torque converter
and epicyclic gear arrangement. If all different devices are combines into one unit,
they will do their duties jointly without any interruptions.

Purpose Of Gearbox
It helps the engine to disconnect from driving wheels.
It helps the running engine connect to the driving wheel smoothly and without
shock.
It provides the leverage between engine and driving wheels to be varied.
This helps in reducing the engine speed in the ratio of 4 : 1 in case of passenger
cars and in a greater ratio in case of heavy vehicles like trucks and lorries.
It helps the driving wheels to drive at different speeds.
It gives the relative movement between engine and driving wheels due to flexing

of the road spring Function Of Gearbox

Torque ratio between the engine and wheels should be varied for fast
acceleration and for climbing gradients.
It provides means of reversal of vehicle motion.
Transmission can disconnect from the engine by the neutral position of the
gearbox.
Gear Ratio
Gear ratios are gear reduction steps in the gearbox. A gear reduction multiplies the
engine torque by gear ratio amount. Torque requirement at the wheel depends on
operating conditions.
For example :
Moving a vehicle from a standstill requires much more torque than the peak torque
of the engine. Therefore the torque multiplies by the first gear ratio.
Once starting the vehicle and moving using first gear, it requires less torque at the
wheels to keep it moving. Hence it requires no multiplication or very less
multiplication.
If the vehicle suddenly encounters a gradient , it will require more torque on the
wheels to keep the vehicle moving. Hence an intermediate ratio requires.

Where Is A Single Plate Clutch?

What Is A Multi Plate Clutch?
What Is A Cone Clutch?
What Is ACentrifugal Clutch?

Advantages And Disadvantages Of

Gearbox
Advantages Of Manual Transmission

The vehicle is more attractive to the driver.

The driver has complete control over the gears and when to shift the gears.
The cost of a manual vehicle is lower than that of an automatic vehicle.
Transmission cost is less for repair.
It provides better mileage.
Disadvantages Of Manual Transmission
Manual transmission can be annoying in heavy traffic.
There may be some problems in learning the new driver.
Precise control over hills is necessary to avoid stalling or rolling back.
Hands and feet can hurt when using gears and clutch.
Advantages Of Automatic

Transmission

It is easy to drive in stop-and-go

traffic.

This transmission is fast and smooth.

Current automated vehicles offer the same mileage as manual transmission.
The automatic transmission is very comfortable for the driver when driving.
Disadvantages Of Automatic Transmission
Buying an automatic transmission vehicle is more expensive than a manual
transmission vehicle.
There are more moving parts in the automatic transmission, which increases the
cost of repair.
The gear change takes a little time and the gear shifting detects, and at times a
slight shock is also failing.
You cannot make the automatic gear more or less at your own will, suddenly
there is a problem in overtaking the car.
FAQ
Q. What is Gearbox?
The gearbox is a mechanical device used to increase the output torque or to
change the speed (RPM) of a motor. The shaft of the motor is connected to one
end of the gearbox and through the internal configuration of gears of a gearbox,
provides a given output torque and speed determined by the gear ratio.

Q. What Is a Gear Ratio?

Gear ratios are gear reduction steps in the gearbox. A gear reduction multiplies
the engine torque by gear ratio amount. Torque requirement at the wheel
depends on operating conditions.