Automotive Gearbox

Prepared

Confirmed

Approved

Aravindhan S POWER TRAIN Gear Box Manufacturing

Lets box the gears

Locating a Gearbox Basics gear - Types of gearing - Gear Manufacturing methods Box Basics Components in a gearbox Linkage from gear knob to gear Gear box Engaged Synchromesh effect clutch gear, rail, fork shift Equalising the differential Options with Gearbox
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Locating a Gearbox

Basics gear
Gear :
A gear is a component within a transmission device that transmits rotational force to another gear or device

Law of gearing (law of conjugacy of gearing)

Constant velocity (i.e., constant ratio) motion transmission is defined as "conjugate action" of the gear tooth profiles is summarized as the Law of Gearing as follows: "A common normal to the tooth profiles at their point of contact must, in all positions of the contacting teeth, pass through a fixed point on the line-of-centers called the pitch point." Any two curves or profiles engaging each other and satisfying the law of gearing are conjugate curves

- Types of gearing
Spur gear Rack & pinion wheel Internal Ring gear

Worm & worm wheel

Bevel gear

Helical gear

- Gear manufacturing method

Automobile gearbox gear manufacturing method gear material : medium carbon high alloy steel ( chromium & molybdenum ) wear resistant, high tensile strength & workable material
Hobbing Shaping

Roll mill

Heat treatment

Forging

Chamfering Deburring

Grinding Shaving

Blank pre machining

Shaving

Gear parameter Inspection

Box basics
Automobile gearbox housing manufacturing methods housing material : Aluminium, earlier cast iron high tensile strength, light weight & workable material
Die casting

Rough Machining

Finish Machining

Final parameter Inspection

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Components in a Gear box Housing

Mechanical Housing

Clutch Housing

Components in a Gear box - Gears

Gears Primary shaft Secondary shaft

Components in a Gear box shift units

Sleeve Rail shift & Fork

Hub

Idler shaft assy

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Cross sectional view of gearbox

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Linkage from gear knob to gear

Driver operates the command shift lever End of lever connects to shift mechanism Shift mechanism to rail shift lug Rail shift lug to sleeve Mobile Sleeve to clutch gear Clutch gear to speed gear ( shaft )

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Gearbox engaged
C.S. of shifter mechanism

Rail shift
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Gearbox engaged
Neutral #1 #3 #5

#2
1 3 5

#4

#R

home condition ( neutral position )

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Synchromesh engaging mechanism

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Synchromesh engaging mechanism

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Synchromesh mechanism

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Equalising the Differential

During a turn the inner ( circle ) wheel takes a shorter distance & outer a longer distance, both at a defined speed and route It transfers & equalizes the power to the front & rear wheel and does not manipulate with gear ratio Noises heard during a turn at high speed is due to slip in differential gear

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Equalising the Differential

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Options with gearbox

Reverse lamp glow Ensure Engine start in neutral Speedometer gear Engine power off @ Traffic Semi automatic transmission / Automated manual transmission Slip less differential drives Transmission control unit Speed control

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Review points
1. How is gear box connected to engine 2. What connects gears to the drive shaft 3. How is the reverse direction achieved automobile 4. Can the speedometer be reversed by driving in the reverse direction 5. Are engagement of two set of gears possible 6. Transmission oil types & effects on gears 7. What connects the gearbox to the wheels 8. Types of automatic gearboxes 9. Reason for old vehicle effect of clutching poor why ? 10. Does mileage gets affected while driving with declutched condition

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