International Journal of Mechanical Engineering and Technology (IJMET)

Volume 9, Issue 3, March 2018, pp. 991–1006, Article ID: IJMET_09_03_102

Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=9&IType=3
ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

MODELING AND ANALYSIS OF CONSTANT

MESH TRANSMISSION SYSTEM ALONG WITH
CASING
Dasari Ajay
Associate Professor, CMR College of Engineering & Technology,
Hyderabad, Telangana, India

A Vishnu Naga Kumar

Student, CMR College of Engineering & Technology, Hyderabad, Telangana, India

ABSTRACT
Transmission System is used to transmit power from engine to axles. Constant
Mesh Transmission System is one of the famous types of Transmission System where
all gears are constantly mesh with each other at all the times. .Transmission is a
mechanism in a power transmission system, which provides controlled application of
the power. Often the term 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 .For modelling of the component a CAD software known as CREO
3.0 is used. In CREO 3.0. some of the basic operations like revolve, extrude, helical
sweep etc are used. Generally, FEA analysis is used to identify the nature and
characteristics of stresses acting on the assembly and evaluating the influence of
load/mass/geometry/boundary conditions over the Constant Mesh Transmission
System. For FEA analysis, software named ANSYS Work Bench 18.0 is used
Keywords: constant mesh transmission system, gear box, Creo-3, FEA, ANSYS
Cite this Article: Dasari Ajay and A Vishnu Naga Kumar, Modeling and Analysis of
Constant Mesh Transmission System Along With Casing, International Journal of
Mechanical Engineering and Technology, 9(3), 2018, pp. 991–1006.
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=9&IType=3

1. INTRODUCTION
This is one of the famous type used in twenty centuries. It this gearbox, all the gears are in
constant mesh with each other all the time. The gears on the main shaft rotate freely without
rotating the main shaft. Constant mesh gear box consists two dog clutches. These clutches are
provided on the main shaft, one between the clutch gear and the second gear and the other
between the first gear and reverse gear. When the left side dog clutch is made to slide left by
means of gearshift lever, it meshes with the clutch gear and the vehicle runs on top speed. If
this clutch slide right and mesh with second gear, than the vehicle runs on second gear speed.

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 Modeling and Analysis of Constant Mesh Transmission System Along With Casing

So in constant mesh gear box we can change the gear ratio by shifting the dog clutch. This
type of gear box is more popular than sliding mesh because it creates low noise and less wear
of gears.

Figure 1 Constant Mesh Gear Box

A gear or cogwheel is a rotating machine part having cut teeth or cogs which mesh with
another toothed part to transmit torque. The use of gear is to increase speed, increase torque
and change direction

2. MODELING
The modeling of Constant mesh gear box along with spur, helical and zero bevel gear will be
considered.

2.1. Basic Formulae for designing of Spur Gear

Diametral Pitch = Number of Teeth / Pitch Diameter
Base Diameter = Pitch Diameter * cos(Pressure Angle)
Whole Depth = (2.2 / Diametral Pitch) + 0.002
Root Diameter = Outer Diameter - (2 * Whole Depth)
Addendum = 1 / Diametral Pitch
Dedendum = Whole Depth -Addendum
Circular Tooth Thickness = Pi / (2 * Diametral Pitch)

For generation of involute curve

BaseRadius = BaseDiameter / 2
Angle = t*90
Cirlen = (PI * BaseRadius * t ) / 2
X_PNT = BaseRadius * cos(Angle)
Y_PNT = BaseRadius * sin(Angle)
x = X_PNT + ( Cirlen * sin(Angle))
y = Y_PNT - ( Cirlen * cos(Angle))
z=0

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 Dasari Ajay and A Vishnu Naga Kumar

Table 1 Calculation of Spur Gear

Main Gear Counter Gear
1 2 3 4 1 2 3 4
Outer
117 105 90 77 30 42 57 70
Diameter
Number of
46 41 35 29 10 15 21 27
Teeth
Pitch
115 102.5 87.5 72.5 25 37.5 52.5 67.5
Diameter
Pressure
20 20 20 20 20 20 20 20
Angle
Width 14 12 11 11 14 12 11 11
Diametral
0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4
Pitch
Base 82.2 23.4 35.2
108.6 96.31 68.12 49.33 63.42
Diameter 3 9 3
Whole 5.50 5.50 5.50
5.502 5.502 5.502 5.502 5.502
Depth 2 2 2
Root 78.6 18.9 30.9
105.9 93.99 65.99 45.99 58.99
Diameter 9 9 9
Addendum 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5
3.00 3.00 3.00
Dedendum 3.002 3.002 3.002 3.002 3.002
2 2 2
Circular
3.92 3.92 3.92
Tooth 3.926 3.926 3.926 3.926 3.926
6 6 6
Thickness
Module 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5

Table 2 Calculations of Spur Gear

Idle Gear Differential Reverse
Big Small Spur Gear Gear
Outer Diameter 64 54 148 79
Number Of Teeth 24 21 59 30
Pitch Diameter 60 52.5 147.5 75
Pressure Angle 20 20 20 20
Width 10 21.5 18 20
Diametral Pitch 0.4 0.4 0.4 0.4
Base Diameter 56.38 49.33 138.604 70.476
Whole Depth 5.502 5.502 5.502 5.502
Root Diameter 52.996 42.996 136.996 67.996
Addendum 2.5 2.5 2.5 2.5
Dedendum 3.002 3.002 3.002 3.002
Circular Tooth
3.926 3.926 3.926 3.926
Thickness
Module 2.5 2.5 2.5 2.52

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 Modeling and Analysis of Constant Mesh Transmission System Along With Casing

3. PROCEDURE FOR HELICAL GEAR

3.1. Basic Formulae for Helix Gear
Transverse module = normal module / cos (helix angle)
Normal circular pitch = pi * normal module
Transverse circular pitch = pi * transverse module
Transverse pressure angle = atan ((tan (normal pressure angle))/(cos (helix angle)))
Outer diameter = pitch diameter + (2 * normal module)
Root diameter = pitch diameter - (2 * 1.25 * normal module)
Base diameter = pitch diameter * cos (transverse pressure angle)
Normal tooth thickness = (pi * normal module) / 2
Transverse tooth thickness = (pi * transverse module) / 2
Lead = pi * Pitch diameter / tan (Helix angle)
Addendum = normal module
Dedendum = 1.25 * normal module
Tooth depth = 2.25 * normal module

3.2. For generation of curve

BaseRadius = BaseDiameter / 2
Angle = t*90
Cirlen = (PI * BaseRadius * t ) / 2
X_PNT = BaseRadius * cos(Angle)
Y_PNT = BaseRadius * sin(Angle)
x = X_PNT + ( Cirlen * sin(Angle))
y = Y_PNT - ( Cirlen * cos(Angle))
z=0

3.3. Calculation of Helical Gear

Number of Teeth = 65
Normal Module = 1.5
Pitch Diameter = 111
Normal Pressure Angle = 20
Helix Angle = 25
Width = 13.5
Side = Right Hand
Transverse Module = 1.655
Normal Circular Pitch = 4.712
Transverse Circular Pitch = 5.199
Transverse Pressure Angle = 21.880203
Outer Diameter = 114
Root Diameter = 106.5
Base Diameter = 103.004

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 Dasari Ajay and A Vishnu Naga Kumar

Normal Tooth Thickness = 23.5619

Transverse Tooth Thickness = 2.5999
Lead = 747.8255
Addendum = 1.5
Dedendum = 1.875
Tooth Depth = 3.375

4. PROCEDURE FOR BEVEL GEAR

Table 3 Calculations of Bevel Gear
Bevel Gear Bevel Gear
Symbol Formula
Pinion (1) (2)
Shaft Angle 900 900
Module m 4.73 4.73
Pressure Angle A 200 200
Number of Teeth Z 22 26
Pitch Diameter d Z*m 104.06 122.98
δ1 atan(z1/z2)
Pitch Circle Cone Angle 40.237 49.763
δ2 90 - δ1
Cone Diameter R d2/2*Sin(δ2) 80.55 80.55
Face Width B < R/3 24 24
Addendum ha 1*m 4.73 4.73
Dedendum hf 1.25 * m 5.1925 5.1925
Dedendum Angle θf aTan(hf/R) 3.688 3.688
Addendum Angle θa aTan(ha/R) 3.3606 3.3606
Tip Angle δa δ + θa 43.5976 52.879
Root Angle δf δ - θf 35.0445 46.075
Outer Diameter Da d+2*hacos(δ) 111.22 129.09
Base Diameter B d * Cos(δ) 79.43722 79.49302
Root Diameter Rd d – 2 * hf 93.675 112.595
Diametral Pitch P z/d 0.2114 0.2114
Whole Depth h (2.2/P) + 0.002 10.4088 10.4088
Circular Tooth Thickness t 1.5708 /P 7.43046 7.43046

Parts List
 Gears of 4 main shaft
 Main shaft
 Reverse shaft with reverse shaft
 Counter Gear of 4 spur and one helical gear
 Idle Gears of big and small
 Differential of 2 sun gears and 2 star gears with a pin and spur gear
 Cross gear, Cross bolt, Cross bolt bush
 Gear Shifter
 Casing of 4 parts

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 Modeling and Analysis of Constant Mesh Transmission System Along With Casing

Figure 2 Four Gear Shaft Assembly

Figure 3 Countershaft assembly

Gear Ratio
The Gear Ratio is defined as the input speed relative to the output speed.

Table 4 Gear Ratio

Gear Ratio Gear
values Ratio
1st Gear 46/10 4.6
2nd Gear 41/15 2.733
3rd Gear 35/21 1.667
4th Gear 29/27 1.074
Reverse Gear: Idle
30/24 1.25
Gear
Idle Gear:
Differential Spur 21/59 0.3559
Gear
Bevel Gear Pinion:
22/26 0.8461
Bevel Gear

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 Dasari Ajay and A Vishnu Naga Kumar

 Lesser the Gear Ratio, Higher the speed and lesser, the torque needed and vice-versa
One of the main benefits of a gear box is it allows you to make adjustments to the speed
and torque of a motor

Figure 4 Main shaft and Countershaft assembly

Figure 5 Assembly of Gears

Figure 6 Main Assembly Isometric View

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 Modeling and Analysis of Constant Mesh Transmission System Along With Casing

5. MATERIAL PROPERTIES
Table 5 Material Properties
High Carbon Medium Carbon Steel Aluminum
Properties
Steel SAE 1055 Alloy
Yield strength (MPa) 350-550 355 280
Tensile strength (MPa) 650-880 650 310
Poisons ratio 0.27-0.30 0.27-0.30 0.33
Density (kg/m3) 7700 7800 2770
Shear modulus (GPa) 80 80 26.692
Thermal expansion coefficient (/k) 10 11 8
Thermal Conductivity (W/m.K) 26 51.9 41.9
High Carbon Steel for Gears
Medium Carbon Steel for Shafts
Aluminum alloy for Casing
SOLID185 is used for 3-D modeling of solid structures. It is defined by eight nodes
having three degrees of freedom at each node: translations in the nodal x, y, and z directions.
The element has plasticity, hyperelasticity, stress stiffening, creep, large deflection, and large
strain capabilities. It also has mixed formulation capability for simulating deformations of
nearly incompressible elastoplastic materials, and fully incompressible hyperelastic materials.
Two Gear Assembly of Main Gear 1 and Counter Gear 1

Figure 7 Total Deformation

Table 6 Equivalent Stress

Time [s] Minimum [MPa] Maximum [MPa]
1. 2.9576e-003 314.21

Figure 8 Equivalent Stress

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 Dasari Ajay and A Vishnu Naga Kumar

Table 7 Safety factor

Time [s] Minimum Maximum
1. 2.0687 15.

Figure 9 Safety Factor Figure 10 status

Table 7 Pressure
Time [s] Minimum [MPa] Maximum [MPa]
1. -7215. 73362

Figure 11 Pressure

Transient Structural Analysis

Figure 12 No separation Connection

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 Modeling and Analysis of Constant Mesh Transmission System Along With Casing

Figure 13 Total Deformation Graph

Figure 14 Total Deformation

Four Gear Pair Assembly

Figure 15 Four Gear Pair Assembly

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 Dasari Ajay and A Vishnu Naga Kumar

Element: Solid 185

Materials used for:
Shaft: Medium Carbon Steel
Gears: High Carbon Steel

6. MODAL ANALYSIS
Table 8 Modal Frequency
Mode Frequency [Hz]
1. 719.17
2. 747.93
3. 1131.8
4. 1908.7
5. 2017.6
6. 2424.4
7. 2538.
8. 2896.4
9. 3152.5
10. 3202.7
11. 3537.
12. 4078.9

Figure 16 Total Deformation

Transient Structural Analysis

Figure 17 Total Deformation Graph

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 Modeling and Analysis of Constant Mesh Transmission System Along With Casing

Figure 18 Total Deformation

MAIN ASSEMBLY

Figure 19 Main Assembly

Element: Solid 185
Materials used:
High Carbon Steel: Gears
Medium Carbon Steel: Shafts
Aluminum Alloy: Casing

Figure 20 Moment and Fixed Supports

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 Dasari Ajay and A Vishnu Naga Kumar

Table 9 Total Deformation

Time [s] Minimum [mm] Maximum [mm]

1. 0. 1.1479e-002

Figure 21 Total Deformation

Table 10 Equivalent Stress

Time [s] Minimum [MPa] Maximum [MPa]

1. 0. 29.664

Figure 22 Equivalent Stress

Modal Analysis
Table 11 Modal Frequencies
Mode Frequency [Hz]
1. 527.47
2. 531.21
3. 897.
4. 898.7
5. 1428.2
6. 1582.6
7. 2023.5
8. 2885.8
9. 3029.9
10. 3186.9

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 Modeling and Analysis of Constant Mesh Transmission System Along With Casing

11. 3847.7
12. 3974.5

Figure 23 Total Deformation in Modal

7. CASING

Figure 24 Casing

Element: Solid 18
Material used is Aluminum Alloy for Casing

STATIC ANALYSIS

Figure 25 Bonded Connections

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 Dasari Ajay and A Vishnu Naga Kumar

Figure 26 Bonded Connections Figure 27 Total Deformation

8. CONCLUSION
Reference value of an existing manufactured product is taken and rest is calculated with the
available formulae. Designing of the model is done in CREO 3.0. Modeling is done using
some operations like sketching, extrude, swept blend, round, etc., Spur gear is designed using
involute curve method along with using some operations like angled datum plane and pattern
commands. Helical gear is designed using involute curve method along with using some
operations like angled datum plane, helical sweep, swept blend and pattern commands. Bevel
gear is designed using some operations like revolve, helical sweep and pattern commands.
The designed model is analyzed in Static, Dynamic and Kinematic modes using ANSYS 18.0.
The obtained values were below the working limits ensuring a safe design.
 Static and Transient Analysis of two gear assembly
 Static, Modal and Transient Analysis of four gear assembly
 Static and Modal Analysis of main assembly
 Static Analysis of Casing
 Yield strength of the material in static structural is 350MPa.
 Obtained values for two gears is 314MPa
 Obtained values for four gear pair assembly is 236.8MPa
 Obtained values for main assembly is 29.664MPa
 From the above values we can conclude the designed model is safe

FUTURE SCOPE OF THE RESEARCH

The future scope of this research is by replacing the material of the components with
extremely low weight and high strength materials. The dog clutch can be engaged or
disengage by hydraulic or pneumatic systems with help of sensors. There can also be a
provision to reduce the number of gears and obtain the same number of speeds. The type of
engagement between the dog clutch and the gear can also be enhanced by some other means.

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V.Bedekar

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