GMSARN International Conference on Sustainable Development: Issues and Prospects for the GMS 12-14 Nov.

2008

Design and Fabrication of Five Speed Manual Gear-box

for Four-Wheel Drive Passenger Car

Mon Mon Zaw

Abstract— This paper presents the design and fabrication of five speed manual gear-box for four wheel drive passenger car
which is intended to attach with 1 HD-T engine (common-rail high version, direct injection turbo engine). In an automobile,
the power train carries the power from the engine to the car wheels and consists of the clutch, transmission, propeller shaft,
differential and wheel axles. The gear-box is one of the most important parts of the power train. In the 1 HD-T engine gear-
box, the five forward speed and one reverse gears are helical type. Gears and shafts are designed with AISI 4150 OQT 1000
heat treated alloy steel. This paper will provide the necessary concepts, design procedure techniques to design shafts and
helical gears. It is also included the calculation of gear ratios from Progressive Gear Steps. The sample counter shaft and
gears assembly is fabricated only to know the manufacturing processes with localized material. The detail drawings and
stress analysis is made by using “Auto Desk” software based on Ansys technology. Road load performance graphs are
described by using MATLAB program.

Keywords— Auto Desk Software, Fabrication, Five Speed Manual Gear-box, 1 HD-T Engine.

5th Gear
1st - 2nd Synchronizer
1. INTRODUCTION 5th Synchronizer 2nd Gear
3rd Gear G9 1st Gear
3rd - 4th Synchronizer G7
G3
All form of motorized transport, including vessels and 4th
Gear G1 G5 G11 Reverse Gear
(Clutch Gear)
aircraft, need transmissions to convert torque and
rotation. The average engine would have power enough Input Shaft
Output
to operate a car without a transmission provided the car Shaft

operated on reasonably level roads and maintained G12

sufficient speed. When the car must be started from a

standstill, or when attempting to negotiate steep grades,
Reverse
the engine would not provided sufficient power and the Idler Gear

car would stall. Much less torque is required to move a

car rolling on level ground than is necessary to drive the
same car up a steep hill. To enable the engine to increase Counter Shaft G8 G10 G13
G4
torque to the drive line, it is obvious that a torque
multiplier (transmission) is needed. By using a G2
G6
Fig .1. Neutral Position Gear Meshing
transmission, it is possible to adapt the available power of
the engine to meet changing road and load conditions.
2. REQUIRED DATA OF 1 HD-T ENGINE
There are two types of transmission, namely, manual
transmission and automatic transmission. Manual To design and analysis of 1 HD-T engine gearbox, the
transmission type is used for so many cars in various required data are collected and assumptions are extracted
models and locations. If the car has a manual gear box, from automotive transmissions handbook.
the driver moves the shift lever to shift gears. Automatic Car type 4WD Passenger Car
gearbox does the job automatically without any effort by Curb weight 1630 kg
the driver. Manual transmission consists of a cast iron or Gross vehicle weight 2590 kg
aluminum housing, shafts, bearings, gears, synchronizing Overall vehicle length 4890 mm
devices and shifting mechanisms. Automatic transmission Overall vehicle width 1940 mm
includes a torque converter, compound planetary gear set, Overall vehicle height 1925 mm
two or more disc clutches and one or more bands. The Tyre type 205/75 R 16
aim of this paper is to obtain the design and working Maximum car speed 180 km/h
procedure for mass production in related fields. Figure1 Engine type 1 HD-T
shows the neutral position of gear meshing. Bore × Stroke 94 × 100
Compression ratio 18.6: 1
Combustion chamber Direct injection type
Displacement 4164 cc
Mon Mon Zaw is with Mandalay Technological University, Maximum power 118 kW at 3600 rpm
Mandalay, Myanmar (Phone: +95-9-5350760; Fax: +95-2-88702; Maximum torque 360 kW at 2100 rpm
Email: okka.gtc@gmail.com, okkamon@gmail.com).

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3. CALCULATION OF GEAR RATIOS equation.
To calculate gear ratios, the following equations are used. For a solid shaft with axial loading, the ASME code
equation is:
iA= iSiGiE (1)
i i1 σF d 
2
iG ,tot= G , max ==== 16 
= (2) d3 = K b M b + a  + (K t M t ) (7)
2
iG , min iz πSs  8 

By using progressive gear step, where Mt = Torsional moment, Nm,

Mb = Bending moment, Nm,
1 Fa = Axial load, N,
ϕ1 = z −1 0.5 ( z −1)( z − 2 )
i G , tot (3)
d = Shaft diameter, m,
ϕ2
Kb = Combined shock and fatigue factor applied
in = iZ φ1(z-n) φ2 (z-n-1) (4) to bending moment
Kt = Combined shock and fatigue factor applied
where, iA= the total power train ratio torsional moment
iS = the moving-off element ratio σ = Column-action factor
iG = gearbox ratio
Table 2. Results of Shaft Design
iE = final drive ratio
From specified car weight, desired tyre size, and Type Sy
Su Dia Length
specification of 1 HD-T engine, the result of gear ratios of Material
(MPa) (mm) (mm)
are as follows; Shaft (MPa)
Input 4150 25-
1st speed = 4.048 Shaft OQT1000
1360 1250
30
244
nd
2 speed = 2.16 Output 4150 21.5-
rd 1360 1250 462
3 speed = 1.36 Shaft OQT1000 50
Count
4th speed = 1 4150 30-
-er 1360 1250 375
th
5 speed = 0.88 OQT1000 45
Shaft

4. DESIGN CALCULATION OF GEARS Idler 4150 27-

1360 1250 110
Shaft OQT1000 28
In gear design, choose AISI 4150 OQT 1000 material
which has Brinell Hardness 401, yield stress 1250 MPa The critical speed of shafts is calculated by using
and ultimate tensile stress 1360 MPa. The diameters of Rayleigh-Ritz equation.
gears are unknown. The center distance is 98 mm. For the
forward speed gears, the design condition was unsatisfied
g1i ∑Wn δ n
with this brinell hardness values. So, the material was ω c= (8)
∑W δ
i
necessary to make heat treatment to get BHN 601. 2
n n
1

Gear designs are calculated by using Lewis Equation.

 1  Sall kπ 2 cos ψ (5) where Wn = Weight of nth mass,
 m2y  = F
  all t
δn = Static deflection at the nth mass and
Sall= 2Mt (6) i = Total number of masses
2
kyπ n m3 cosψ
Table 3. Results of Critical Speed from Shafts
where Mt = Torque in weaker gear, Nm
Ft = Transmitted force, N Type of Shaft Min: and Critical Remark
Max: Speed Speed
n = Number of teeth on weaker gear (rpm) (rpm)
m = Number of module Input Shaft 2100 - 3600 393618 The
Output Shaft 480 - 4113 357231 first
y = Form factor
Counter Shaft 1600 - 2742 199658 critical
k = 6 for helical gear(upper limit) Idler Shaft 770 - 1316 305397 speed is
ψ = Helix angle of gear tooth form consid-
ered.
Sall = Allowable stress
6. MANUFACTURING PROCESS OF COUNTER
Table 1 shows the results of gear meshing. SHAFT AND GEARS ASSEMBLY
5. SHAFT DESIGN CALCULATION In the practical implementation of the sample production
elements for counter shaft, the processing of
The shafts are designed according to the point of view of manufacturing methods and heat treatments need to be
the strength and critical speed. The shaft design considered.
calculations are mainly based on the ASME code

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 Table 1. Results for Gear Meshing

Gear
1st 2nd 3rd 4th 5th R
Pair

Particular G9 G10 G7 G8 G3 G4 G1 G2 G5 G6 G11 G12 G13

Pitch Dia
149 47 126 70 105 91 85 111 79 117 145 90 45
(mm)

No. of teeth 43 13 39 23 38 33 34 44 32 47 43 25 13

Torque
1470 / 470 826 / 470 536 / 470 360 / 470 317/ 470 1553 / 970 /470
(Nm)

Helix angle 23 30 30 30 30 23

Gear ratio 4.048 2.16 1.36 1 0.88 4.313

Face Width
25 21.5 22 25 23 27
(mm)

Module No.
3.5 3 2.75 2.5 2.5 3.5
(mm)

Addendum
3.5 3 2.75 2.5 2.5 3.5
(mm)

Dedendum
4.05 3.471 3.182 2.893 2.893 4.05
(mm)

Clearance
0.55 0.471 0.432 0.393 0.393 0.55
(mm)

Tooth
thickness 5.5 4.71 4.32 3.93 3.93 5.5
(mm)

The desired gear blank is fixed on three jaws of Semi-
Auto Lathe to make turning and facing roughly. And
then, it is placed on Engine Lathe by fitting spindle with
jig to fine turning and facing for required dimensions.
Drilling machine could be used to drill the gear blank for
desired hole. After drilling, the gear needs to spline
internally on Broaching Machine. To form gear tooth, the
gear blank is attached on Hobbing Machine and fed with
desired size hobbing cutter. The gear can get surface
harden by making with High-Frequency Induction
Hardening Machine. The surface of the gear is grinded
with Surface Grinder. In Chamfering Machine, the gear
must be chamfered the edges of gear tooth for smooth
running. Carburizing process adds carbon to the gear to
improve chemical properties. After carburizing, the final
tooth grinding has been taken. The procedures of all six
gears are the same.
The first process of counter shaft production is to cut
the raw material on Sawing Machine to get required
length. After that the raw shaft is placed on Copy Lathe
and turning and facing can be done not only for rough but
also for fine. The shaft is externally splined by using
Spline Hobbing Machine. After this process, the shaft is
placed in the furnace to heat treat by Quenching Method.
And then it is taken out from the furnace and immersed in
salted water to harden the material. It needs to chamfer
and fine cylindrical grind before finishing.

3
 After getting gears components and counter shaft, these
parts are fitted in order their positions. To get more
tightening and strength, welding between shaft and gears
has been done. And then final carburizing is made the
whole counter shaft and gears assembly. The fine
grinding must be done as ending process for sample
counter shaft and gears assembly. Figure 2 shows the
sample product of counter shaft and gears assembly.
for counter shaft in five speed manual gearbox when the
gears are in first speed position. Figure 4 shows the forces
acting on the counter shaft. W2, W4, W6, W8, W10 and
W13 are 16.67N, 11.77N, 16.67N, 10.3N, 4.9N and 4.41N
respectively. Fa2, Fr2 and Ft2 are 4804.4N, 3028.8N and
8321.5N respectively. Fa10, Fr10 and Ft10 are 8417.25N,
7217.5N and 19830N respectively.

W2+Ft2

W4
Fa2
W6 Fr2
W8
W10

W13 Fa10

Fr10
Ft10

Fig.2. Sample Product of Counter Shaft and Gears Fig.4. The Forces Acting on Counter Shaft
Assembly
The sample counter shaft and gears assembly is
fabricated only to know the manufacturing processes with
localized material.

7. ANALYSIS OF STRESSES BY USING AUTO

DESK SOFTWARE 2007
The following procedure is to analysis the stresses,
deformation and safety factor of a given model by using
the program Auto Desk.

Model of
drawing for
Counter Shaft

Selection of Fig.5. Maximum Principal Stress on Counter Shaft

Materials

Restraint of
work piece

The loads To select the

changed due to Loads on the
the operation surface

To run the Analysis

program by Results
iteration method

Minimum principal Maximum To run the Fig.6. Minimum Principal Stress on Counter Shaft
stress distribution principal stress program by
in the model distribution in iteration method As shown in Figure 5, the maximum principal stress,
the model the maximum and minimum stresses are 416.091MPa and
Fig.3. Stress Analysis Procedure of Auto Desk Software 87.264MPa respectively. From Figure 6 the maximum
2007 and minimum stresses are 95.344MPa and 362.791MPa
respectively. But the actual maximum stress acting on the
The following figures represent the stresses distribution
counter shaft, the yellow color is 248.306 Mpa in

4
maximum principal stress and the strong green color is   n   n 
2
 n 
3

159.175 Mpa in minimum principal stress. The maximum N e = N max a   + b  − c  
stresses on the counter shaft due to the first operation are   n N max   n N max   n N max  
less than the permissible strength of material.
8. PERFORMANCE ANALYSIS OF 1 HD-T
ENGINE GEARBOX (9)
where,
The graph of the forces opposing vehicle motion and
engine performance characteristics which provides the nNmax = Number of revolutions per minute
background to the need for a wide range of gearbox corresponding to the maximum horsepower of an engine,
designs used for different vehicle applications will be nMmax = Number of revolutions per minute
considered as necessity of a gearbox. Top gear ratio is corresponding to the maximum torque of an engine,
selected so that the maximum road speed corresponding
to the engine speed at which the maximum brake power is nmin = Minimum number of revolutions per
obtained. minute,
Nmax = Maximum engine power in b.h.p,
bhp,kgm Mmax = Maximum engine torque in kg.m,
N(max) n = Number of revolutions in r.p.m. which
corresponds to Ne and
M(max) a,b,c = Coefficients which are different for
different types of engines.
After the values of horsepower Ne have been found, it
is easy to determine the values of engine torque Me and to
Rpm plot its curve with the aid of the following formula.

n(min) n(Mmax) n(Nmax) n(max) Ne

Me=716.2 (10)
n
Fig.7. Typical Engine Performance Graph Where Me is the engine torque in kilogram meter.
Tractive force is the force transmitted from the engine
to the driving wheels. For a moving automobile, the
tractive resistance FZ is equal to the sum of all resistance.
The formula of Equation 3.5. became;
M e Rg η T
FZ= =FRo+FSt+FL+Fa (11)
rr
where Me = Effective torque of the engine in Nm,
Rg = Overall gear ratio of the transmission,
ηT = Overall efficiency of the transmission and
rr = Radius of wheel in meter.

Fig.8. Traction Diagram of Tractive Effort and Total

The car velocity is calculated by the following formula,
Running Resistance vs Road Speed N 60
The acceleration and climbing performance in the Va=2πrr (12)
rgb ro 1000
various gears of the transmission must be checked. In the
traction diagram, the traction available in each gear and where N = Number of revolutions of the engine in r.p.m,
the traction required at various gradients are plotted as a
function of the vehicle speed. The traction available is rgb= Gear ratio of the gear-box and
reduced by the power-train efficiency, ηtot, which also ro = Gear ratio of the main drive.
includes the effect of losses due to accessories such as
According to the selected tire type, the rolling diameter
servo pumps.
(D) of the specified type of wheel is calculated by using
Maximum values of the horsepower are different from
the following equation.
different engines but the shapes of the power cures are
similar. The typical characteristics may be obtained with H
the aid of empirical formulas. One of them giving the D=2B× +d=2H+d (13)
most exact data and suggested by prof. Leiderman is of B
the following form. where B = Width of the wheel tire cross sectional area,
where Ne = Horsepower of an engine in b.h.p, m,
d = Diameter of the wheel rim, m,

5
 H The air resistances in various gradient road levels are
= Aspect ratio and nearly constant from car speed up to 40 km/hr and then
B gradually increased which depend on gradient angle. The
H = Radial thickness of wheel, m. maximum tractive force is occurred in engine speed 2800
rpm in every gear step.
The rotational speed of wheel (rpm)wheel is calculated by
The results of calculated road load performance for
the following formula. five speed 1 HD-T engine gearbox are described in Table
4. The road load performance graphs for gradient 0, 2 and
V 4 percentage are described as follows.
(rpm)wheel= (14)
π D
The rotational speed of engine (rpm)engine is calculated by
the following formula.

(rpm)engine=(rpm)wheel×Rg (15)

where Rg is the overall gear ratio. The overall gear ratio is

calculated by;
Rg=rgb×ro (16)
According to the local test facilities, the road load
performance analysis of 1 HD-T engine gearbox is
calculated. Calculated road load performance graph is run
with MATLAB program. In performance analysis of Fig.9. Graph of Road Load Performance for Level Road
1 HD-T engine gearbox, the road load performance for
gradient 0(level road), 2 and 4 percent are calculated.
In the calculated road load performance graph, car
speed and tractive force resistance are plotted. The
tractive force resistance (FZ) curve is plotted for each gear
in the gearbox. The two lines FRO and FSt correspond to
the rolling resistance and the gradient resistance,
respectively. As both resistances do not depend on the
speed the indicated lines are parallel to the velocity axis.
The curve FL corresponds to the air resistance which is
proportional to the square of the speed. So, the function F
= f (Va) for FL is expressed by a curve.
Figures 9, 10, and 11 represent the graphs of road load
performance of a 1 HD-T engine gearbox for gradient 0,
2 and 4 percent. In these figures, the violent color curve is
the total tractive force resistance for 5th gear, which is the
sum of air resistance, wheel resistance, gradient
resistance and inertia force resistance. In these figures, Fig.10. Graph of Road Load Performance for Gradient 2
wheel resistance (FRO) and radient resistance (FSt) Percent
Table 4. Results of Calculated Road Load Performance

Tractive Force
Car Speed
Position Resistance
(km/hr)
(kg)

1st Gear 18 – 30 1345

2nd Gear 32 – 54 756

3rd Gear 49 – 83 491

4th Gear 72 – 124 332

5th Gear 82 – 141 330

Reverse 17 - 29 1422
vary with each gradient angle. Tractive force resistances Fig.11. Graph of Road Load Performance for Gradient 4
are not varied because of using the same gearbox. The Percent
lower the gear number in the gearbox, the higher the
tractive force resistance. Advantage of using MATLAB program of calculated

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road load performance is the graphs of variety of In this five speed manual gearbox design, to complete
gradients are plotted automatically. The plotted tractive the whole gearbox design, the casing, the hub sleeve ring
characteristic of an automobile enables to solve some gears, synchronizer cone and synchronizer ring design
tractive problems, to write the tractive balance equation should be calculated for further study of the more proven
for any given speed, and to determine the nature of an design. The analyses are made for only counter shaft in
automobile motion and the resistances overcome by an this paper and if the other shafts and gears could be
automobile. analyzed, the design of transmission can be effectively
improved. Finally, the design calculation methods of
9. CONCLUSION AND DISCUSSION
gears and shafts of this paper can be provided for any
In this paper, the design and analysis of 1 HD-T engine automobile gearbox.
gearbox has been described. In this gearbox, there are all
together five forward speed and one reverse. Among the ACKNOWLEDGMENTS
five forward speeds, the fourth drive is the direct drive The author wishes to express heartfelt gratitude to her
and the final drive is the overdrive. supervisor Dr. San San Yee, Professor, Department of
By considering the road load performance of the car Mechanical Engineering, West Yangon Technological
speed and engine speed, the progressive gear step method University and co-supervisor Dr. Than Than Htike,
is used and the gear ratios are evaluated. From this result, Associate Professor and Head, Department of Mechanical
assumption for the center distance which is based on the Engineering, Pyay Technological University, for their
maximum torque of the input speed from the engine is willingness to share the ideas, invaluable knowledge,
desired and then solved for the number of teeth and gear helpful guidance, suggestions and experience and
parameters. Then rechecking the speed ratio range, the correction on this paper.
exact gear ratio for the design can be calculated. The author would like to express the deepest gratitude
In continuation, helical gears and shafts designs are to beloved parents and the teachers from Mechanical
calculated. In this design, structural rigidity combined Engineering Department, Yangon Technological
with lightness must always be the first consideration for University, for their noble support and encouragement to
the durability of the wearing parts and smoothness of attain the destination without any trouble.
running.
Gears and shafts are designed with 4150 OQT 1000 NOMENCLATURE
heat treated alloy steel, which has brinell hardness 401,
yield stress 1250 MPa and ultimate stress 1360 MPa. The Symbol Description SI Unit
required design calculation of helical gears can also be D Gear diameter mm
calculated through both strength and dynamic check. The d Shaft diameter mm
shafts are designed according to the point of view of the E Modulus of elasticity N/mm2
strength and critical speed. In the shaft design, the shaft F Force N
diameters for variety of speeds calculated by using the f Coefficient -
ASME code equation. In addition, it is continued to G Modulus of rigidity N/mm2
check the critical speed of the shafts with overestimation g Acceleration, due to gravity m/s2
method. I Moment of inertia m4
In manufacturing process, the sample product is only i Ratio -
counter shaft and gears assembly because of time and L Length m
cost limits. The material used in all the manufactured M Bending moment Nm
sample shaft and gears is alloy steel which has the nearly m Module mm
chemical compositions to AISI 4150 OQT 1000 material. N Rotational speed rpm
In this manufacturing of sample products, low grade high n Number of teeth Teeth
strength alloy steel which is imported from china is used. r Wheel radius m
Analyses of maximum and minimum principal stresses, S Permissible stress N/mm2
deformation and safety factor for counter shaft are Greek Letters
computed by using Auto Desk 2007 software. Model of ψ Helix angle Degree,°
drawing for counter shaft are drawn. And then material φ Gear step -
selection and restraint work piece are made. The specific σ Column-action factor -
alloy steel and selected bearings are placed for counter η Efficiency -
shaft. After giving the loads acting on the counter shaft, δ Shaft deflection mm
the program runs by iteration method. By using Ansys ω Angular velocity rad/s
technology under Auto Desk soft ware, the variety graphs
are plotted automatically. REFERENCES
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7
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