Академический Документы
Профессиональный Документы
Культура Документы
PROGRESSIVE GEARBOX
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
Submitted by
AMAL VENIS.W
81908144501
ANANTHA KUMAR.K
81908144502
I certify that the declaration made above by the candidate is true.
SIGNATURE
Dr.V.GOPALAKRISHNAN
Professor,
Mechanical Engineering,
Saranathan College of engineering.
Trichy -12.
2
BONAFIDE CERTIFICATE
This is to certify that the dissertation entitled “PROGRESSIVE GEARBOX” is a bonafide work
carried out by
AMAL VENIS.W 81908144501
ANANTHA KUMAR.K 81908144502
under my direct supervision is submitted in partial fulfillment of the requirements for the award
of degree of Bachelor of Engineering in MECHANICAL ENGINEERING to Anna University
of Technology Tiruchirappalli, Tiruchirappalli – 620 024. No part of the dissertation has been
submitted for any degree/diploma or any other academic award anywhere before.
SIGNATURE
Dr.V.GOPALAKRISHNAN
SUPERVISOR
Forwarded by
SIGNATURE
S.CHINNATHAMBI
HEAD OF THE DEPARTMENT
3
ACKNOWLEDGEMENT
We would like to thankful our workshop instructors for their valuable support
throughout our project
We would like to thank all our staff and technical assistants for their support and
help rendered by them in completing this project successfully.
4
ABSTRACT
This project mainly deals about design and fabrication of self progressing gear box. A
gear box is an assembly of gears which is used for controlling the speed and has many
applications widely, even in automobiles gear box is implemented and various improvements are
done day by day. One of the improvements done in gear box is auto changing. In our project a
prototype of this gearbox for auto changing for gears is done with the help of a governor
mechanism. The assembly consists of a set of gears connected to the motor through the governor.
The governor is attached to the driver shaft. At initial position there will be no engagement of
gears for power transmission. When the speed begins to increase in the driver shaft due to
presence of the governor the initial height reduces and the shaft moves and engages with the first
gear and power is transmitted to the driven shaft. As the speed further increase in speed will
cause the second gear to engage. And vice versa when the speed reduces and the driver shaft will
return to the initial position with the help of the spring. The design procedures, drawings for the
above mentioned project is given below.
5
TABLE OF CONTENT
ABSTRACT v
LIST OF TABLES vi
1 INTRODUCTION 1
2 LITERATURE REVIEW
3 DESCRIPTION OF COMPONENTS 2
3.1 GEAR 2
3.3 GOVERNOR 12
4 PART DIAGRAM 13
5 ASSEMBLY DIAGRAM 14
6 WORKING PRINCIPLE 16
7 DESIGN CALCULATION 18
8 APPLICATIONS 22
9 ADVANTAGES 23
10 LIST OF MATERIAL 24
11 COST ESTIMATION 25
12 CONCLUTION 26
6
INTRODUCTION
A progressive gearbox is a gearbox which changes the gear according to speed variation.
This movement for the gears based on speed is done with the help of governor. Its main
function is to shift the gears in forward as speed increases and vice versa when the speed
decreases. The governor plays vital role in changing of gears. By using a prime mover
(Motor) and governor mechanism the forward and reverse motion of driving shaft is
achieved.
7
DESCRIPTION OF COMPONENTS
GEAR:
INTRODUCTION
Gears are toothed wheels used for transmitting motion and power from one shaft to
another when they are not too far apart and when constant velocity ratio is desired. In
comparison with belt, chain and friction drivers, gear drives are more compact, can operate
at high speeds and can be where precise timing is required. Also gear drives are used when
large power is to be transmitted. The force required to hold the gears in position is much less
than in an equivalent friction drive. This results in lower bearing pressure, less wear on the
bearing surface.
Advantages and Limitation of Gear Drive over Chain and Belt Drives
Advantages:
Since there is obtained no slip, so exact velocity ratio is obtained.
It is capable of transmitting larger power than of the belt and chain drives.
It is more efficient (up to 99%) and effective means of power transmission.
It requires less space as compared to belt and rope drives.
It can transmit motion at very low velocity, which is not possible with the belt
drives.
Limitations:
The manufacture of gears requires special tools and equipments.
The manufacturing and maintenance costs are comparatively high.
The error in cutting teeth may cause vibrations and noise during operations.
Definition of Gear
A circular body of cylindrical shape or that of the shape of frustum of a cone and of
uniform small width, having teeth of uniform formation, provided on its outer
circumferential surface, is called a gear or toothed gear or toothed wheel.
8
CLASSIFICATION OF GEARS
Gears may be classified in different manners as given below :
Classification based on the relative position of their shaft axis:
Parallel shafts
Examples: Spur gear, helical gear, rack and pinion and internal gears.
Intersecting shafts
Examples: Bevel gears and spiral gears.
Non-parallel, non-intersecting shafts
Examples: Worm, hypoid and spiral gears.
Classification based on the relative motion of the shafts:
Row gears: In this type, the motion of the shafts relative to each other is fixed.
Planetary and differential gears
Classification based on peripheral speed (v):
Low velocity gears - v < 3 m/s
Medium velocity gears - v = 3 to 15 m/s
High velocity gears - v > 15 m/s
Classification based on the position of teeth on the wheel:
Straight gears Herringbone gears
Helical gears Curved teeth gears
Classification on the type of gearing:
External gearing
Internal gearing
Rack and pinion
But from our subject point of view, gears are broadly classified into four groups,
viz., spur, helical, bevel and worm gears.
Spur gear (sometimes called straight spur gears) have teeth parallel to the axis of
rotation are used to transmit motion from one shaft to another parallel shaft.
Helical gears have teeth inclined to the axis of rotation. The double helical gears
connecting two parallel shafts are known as herringbone gears.
Bevel gears have teeth formed on conical surfaces. They are mostly used for
transmitting motion between intersecting shafts.
9
Worm gears consist of a worm and a wheel can be visualized as a screw and nut
pair. They are used to transmit motion between non-parallel non-intersecting shafts.
SPUR GEAR
In spur gears, the teeth are straight and parallel to the axis of the wheel. The gearing
so formed is called spur gearing. They are used to transmit rotary motion between parallel shafts
.This gearing may be internal or external. External gears rotate in opposite directions while
internal gears rotate in the same direction.
The various terms used in the study of gears have been explained below.
Pinion: A pinion is the smallest of two matting gears. The larger is often called the gear
or the wheel.
Pitch circle: It is an imaginary circle which by pure rolling action, would give the same
motion as the actual gear.
Pitch circle diameter: It is the diameter of the pitch circle. The size of the gear is usually
specified by pitch circle diameter. It is also called as pitch diameter.
10
Pitch point: It is a common point of contact between two pitch circles.
Pitch surface: It is the surface of the rolling discs which the meshing gears have replaced
at the pitch circle.
Pitch: Pitch of two matting gears must be same. It is defined as follows:
Circular pitch (pc):
It is the distance measured along the circumference of the pitch circle from a point on
one tooth to the corresponding point on the adjacent tooth.
πD
Circular pitch, pc =
z
Addendum circle (or Tip circle): It is the circle drawn through the top of the teeth and
concentric with the pitch circle.
Addendum: It is the radial distance of a tooth from the pitch circle to the top of the
tooth.
Dedendum circle (or Root circle): It is the circle drawn through the bottom of the circle.
Dedendum: It is the radial distance of a tooth from the pitch circle to the bottom of the
tooth.
Clearance: It is the radial distance from the top of the tooth to the bottom of the tooth, in
a meshing gear. A circle passing through the top of the meshing gear is known as clearance
circle.
Total depth: It is the radial distance between the addendum and the dedendum of a gear.
Total depth = Addendum + Dedendum
Working depth: It is the radial distance from the addendum circle to the clearance circle.
It is equal to the sum of the two meshing gears.
11
Tooth thickness: It is the width of the tooth measured along the pitch circle.
Tooth space: It is the width of the space between the two adjacent teeth measured along
the pitch circle.
Backlash: It is the difference between the tooth space and the tooth thickness along the
pitch circle.
Backlash = Tooth space – Tooth thickness
Face width: It is the width of the gear tooth measured parallel to its axis.
Top land: It is the surface of the top of the tooth.
Bottom land: The surface of the bottom of the tooth between the adjacent fillets.
Face: Tooth surface between the pitch circle and the top land.
Flank: Tooth surface between the pitch circle and the bottom land including fillet.
Fillet: It is the curved portion of the tooth flank at the root circle.
Pressure angle (φ): It is the angle between the common normal to two gear teeth at the
point of contact and the common tangent at the pitch point. The standard pressure angles are
14.5˚and 20˚.
Path of contact: It is the path traced by the point of contact of two teeth from the
beginning to the end of the engagement.
Length of path of contact: It is the length of the common normal cutoff by the
addendum circles of the wheel and pinion.
Arc of contact: It is the path traced by a point on the pitch circle from the beginning to
the end of arrangement of a given pair of teeth. The arc of contact consists of two parts. They are
:
Arc of approach : It is the portion of the path of contact from the beginning of the
engagement to the pitch point.
Arc of recess : It is the portion of the path of contact from the pitch point to the end of
the engagement of a pair of teeth.
Velocity ratio: It is the ratio of speed of driving gear to the speed of the driven gear.
NA zb
ί = NB=za
12
Contact ratio: The ratio of the length of arc of contact to the circular pitch is known as
contact ratio. The value gives the number of pairs teeth in contact.
LAW OF GEARING
The law of gearing states that for obtaining a constant velocity ratio, at any instant of
teeth the common normal at each point of contact should always pass through a pitch point,
situated on the line joining the centers of rotation of the pair of matting gears.
The law of gearing states the condition which must be fulfilled by the gear tooth
profiles to maintain a constant angular velocity ratio between two gears. This is the fundamental
condition which must be satisfied while designing the profiles of the teeth of gear wheels.
13
Involute tooth profile and Cycloidal tooth profile
Involute Tooth Profile
An involute is defined as the locus of a point on a straight line which rolls without
slipping on the circumference of a circle. Also, it is the path traced out by the end of a piece of
taut cord being unwound from the circumference of a circle. The circle on which the straight line
rools or from which the cord is known as the base circle.
Cycloidal Tooth Profile
A cycloid is the curve traced by a point on the circumference of a circle which rolls
without slipping on a straight line. It is difficult to manufacture as two curves hypo and
epicycloid are required. Center distance should not vary. Less wear and tear as concave flank
makes contact with convex flank.
STANDARD SYSTEMS OF GEAR TOOTH
The American gear manufacturers Association (AGMA) and National Standards
Institute (ANSI) standardised the following four forms of gear teeth depending upon the pressure
angle.
14.5˚ composite system,
14.5˚ full depth involute system,
20˚ full depth involute system, and
20˚ stub involute system
In actual practice, the 20˚ involute system is widely used.
Advantages of 14.5˚ Involute System
It provides smooth and noiseless operation.
It has stronger tooth.
Advantages of 20˚ Involute System
It reduces the risk of undercutting.
It has stronger tooth with a higher load carrying capacity.
It has greater length of contact.
14
STANDARD PROPORTIONS OF GEAR SYSTEMS
The table shows the standard proportions in module for the gear systems.
S.No. Particulars 14.5˚composite or full 20˚ full depth 20˚ stub
depth involute involute system involute
system system
1 Addendum 1m 1m 0.8 m
2 Dedendum 1.25 m 1.25 m 1m
3 Working depth 2m 2m 1.6 m
4 Minimum total 2.25 m 2.25 m 1.8 m
depth
5 Tooth 1.5708 m 1.5708 m 1.5708
thickness m
6 Minimum 0.25 m 0.25 m 0.2 m
bottom clearance
7 Fillet radius at 0.4 m 0.4 m 0.4 m
root
15
GEAR BOX
INTRODUCTION
We know that machine tools like lathe, milling machine, etc., require a wide range of
spindle speeds. Because a machine tool is adoptable for cutting different types of metals having
different properties using varying grades of cutting tools on work pieces of different diameters.
Thus the provision of variable spindle speed is necessary in order to meet different requirements.
The various methods used for obtaining different speeds of machine tool spindle are as follows :
By using a gear box mechanism,
By using a cone pulley arrangement,
By using a variable speed electric motor, and
By hydraulic operation.
Among these methods, the gear box method is very popularly used.
REQUIREMENTS OF A SPEED GEAR BOXES
A speed gear box should have the following requirements :
It should provide the designed series of spindle speed.
It should transmit the required amount of power to the spindle.
It should provide smooth silent operation of the transmission.
It should have simple construction.
Mechanism of speed gear boxes should be easily accessible so that it is easier to
carry out preventive maintenance.
NECESSITY OF A GEAR BOX
To regulate torque by selecting the appropriate speed range.
To regulate vehicle speed at which maximum torque is available.
To balance the tractive effort with the sum of the various forces tending to oppose
the motion.
16
TYPES OF GEAR TRANSMISSION
Gear Boxes are generally classified as
Selective type
Progressive type
Epicyclic or Planetary type
Selective type is further classified as
Sliding mesh
Synchro mesh
Constant mesh
Other special classifications are
Over drive
Chrysler semi-automatic
Automatic
Hydromatic drive
Torque converter gear box.
SLIDING MESH GEAR BOX
It is the oldest and simplest form of gear box. Sliding type gear boxes are quite
commonly used in general purpose machine tools. In order to mesh gears on the main shaft with
appropriate gears on the spindle shaft for obtaining different speeds, they are moved to the right
or the left. It derives its name from the fact that the meshing of the gears takes place by sliding of
gears on each other.
CONSTANT MESH GEAR BOX
It derives its name from the fact that all the gears whether of the main shaft are in
constant mesh with each other. It is also known as a silent or quite gear box. It gives a quieter
operation and makes gear changing easier by employing helical gears for the constant mesh. In
order to connect the required gear wheel by means of teeth on the side of the gear wheel, a
separate sliding member is employed.
17
GOVERNOR
18
Centrifugal governor
19
WORKING PRINCIPLE
The working of this gearbox is same as ordinary gearbox except for the gear shifting
automatically as the speed increases.
As initial in rest position no gears will be engaged and hence no power transmission for
the driving to the driven wheel is obtained.
Then when the driving shaft begins to rotate due to the centrifugal force the governor
begins to expand.
Since the governor is attached to the driving shaft the sliding shaft also slides towards the
governor.
As the driving shaft attains a particular speed the first set of gears will begin to engage
and power is transmitted to the driven shaft.
Even further improvement in speed ill cause the 2nd set of gears to engage.
Then as the speed reduces due to the spring force the sliding shaft will move away from
the governor.
And it finally disengages from all gears and comes to neutral position.
NEUTRAL POSITION
20
FIRST GEAR ENGAGEMENT
21
DESIGN CALCUALTION
To design a gear drive with no of teeth on pinion as 27 and no of teeth on gear 33 the centre
m( z1 z 2 ) m( 27 33)
a => 60= => m = 2mm
2 2
Addedendum = D1+2*m
=54+2*2 = 58mm
Dedendum = D1 - 2(m+c)
Clearance c = 0.25 * m = 0.25 * 2 = 0.5mm
= 54+2(2+0.5)
=49mm
22
SPECIFICATION OF GEAR
Module 2 mm 2mm
No of teeth 27 33
23
SPECIFICATION OF GOVERNOR
R
The arm length l = 80 mm
The initial height of the governor h = 61.28mm
Initial radius at rest r = 51.42mm
Initial angle = 40°
The mass attached m = 0.5kg
H
2∗𝜋∗𝑁 2 3∗9.81+50
0.5 * ( ) *0.059*0.054 = ( )* 0.059
60 2
N = 366.24 rpm
2∗𝜋∗𝑁 2 3∗9.81+50
0.5 * ( ) *0.069*0.041 = ( ) * 0.069 N = 420.31 rpm
60 2
24
OPERATION SPECIFICATION
ST
1 GEAR 366.22 53.78 59.22 300
ND
2 GEAR 420.31 41.28 68.53 514
25
ADVANTAGES
26
APPLICATION
27
BILL OF MATERIALS
28
COST ESTIMATION
29
CONCLUSION
A brief explanation about the progressive gearbox is given in the above. Even though these types
of gearboxes are only introduced in latest automobile vehicles but in the future this gearbox can
be the dominating one. Even though lot of improvement can be done our project only a prototype
is don for learning purpose. And I finally like to thanks all who helped me in completing this
project.
30