MSP5003 Auto and component design

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AUTO AND COMPONENT DESIGN MSP5003UNIVERSITY OF BOLTONMSP5003 - Auto and Component DesignTITLE: Report onGearbox Specification and 3D modellingAUTHOR: VIJAY KADIR RJ (1607306)LECTURER: ROBERT HIGHAM1|P a g eV I J A Y K A D I R
AUTO AND COMPONENT DESIGN MSP5003UNIVERSITY OF BOLTONTable of ContentsABSTRACT..............................................................................................................................................3INTRODUCTION.....................................................................................................................................5DESIGNING GEARBOX PROCESS.............................................................................................................6CALCULATION:.......................................................................................................................................7MATERIALS..........................................................................................................................................12COST ESTIMATION...............................................................................................................................14MANUFACTURABILITY.........................................................................................................................15METHODOLOGY...................................................................................................................................17CONCLUSION:......................................................................................................................................18RECOMMENDATIONS..........................................................................................................................19References...........................................................................................................................................20APPENDIX:...........................................................................................................................................222|P a g eV I J A Y K A D I R
AUTO AND COMPONENT DESIGN MSP5003UNIVERSITY OF BOLTONABSTRACT: Designing a gearbox is done by taking and assemblingthe many gears in required ratios of speed to come up with the endspeed that is to be produced. A gearbox posses many types of gearsthat are combined in proper synchrony that allow reduction ofspeed. Some of the gearbox types include; synchronic mesh gearbox,sliding mesh gearbox and constant mesh gearbox. Taking note of thesliding mesh gearbox, we are provided with two types, stationerygears and sliding gears. Most applications of a sliding gear aremounting it on to shafts that are splined making them function asthey slide along a shaft of an axis that allows different pair meshingof the gears. These gearboxes alternatively can be made better inusing many ways since the system of transmission is manual and hasa number of disadvantages. Such improvements are possible by useof different methods or its improvement done by improving theselection of gear stepping and their ratios. Such factors that affectthese improvements are; fuel consumption, vehicle performance andpollution rate. All these factors are improved by gear ratio varying inthe transmission system. Hence, the transmission system has to bedesigned having ratio gears that are optimal allowing optimumvehicle performance as well as reduced consumption of fuel makingthe technology more friendly to the environment. If there is need toimprove the gearbox’s performance, there is required care inselecting ratios of intermediate gears. The design of the project wasfinally patched in using an analysis of solid works that analysed manyfactors that were known to be essential.3|P a g eV I J A Y K A D I R
AUTO AND COMPONENT DESIGN MSP5003UNIVERSITY OF BOLTONINTRODUCTION:The major reasoning for having a gearbox in vehicles it to facilitatethe transfer ofpowerthat comes from engines to be directed to thewheels via the driveshaft.Using various gears allows equally varioustorque levels that are to be directed to the vehicle wheels with adependence to the speed that the vehicle moves changing the levelof torque requires the gears being used to be shifted by automatic ormanual means, this depends on the transmission type understudy[ CITATION Sal15 \l 1033 ].The manual model that was produced first came from Louis-Rene inunison with Emile Levassor. Their invention involved a transmissionsystem that allowed transmission of three speeds in 1894. Theyproduced the design that is the major point of starting for numerousmanual transmission system. Levassor and Panhard made use ofchain drives in the first transmission system. However, in the yearthat came afterwards, 1898 Louis Renault used the first design thatwas present and improved it to another level using the substitutionof the driveshaft to make use of a drive chain with an addition ofvarious axle that was applied in the rear wheels ton increasetransmission in the designed manual system. This design was key aswhen the 20 the century began, most manufacturers of cars had touse the non-synchronized transmission that was manual thatrequired improvement taking note of the past designedLevassor/Panhard/Renault designs. The invention that followed wasthe year 1928. Cadillac made use and developed a better-synchronized transmission system that was manual, with the addedreduction in gear grinding and easier shifting of gears[ CITATION Sel16 \l1033 ]. The improvement also had smooth gear shifting. There is astudied basic gear system evolution concerning the manual gearbox.The use of helical gears is the preference that is chosen first fordesigning this gearbox due to the quiet and smooth operation of thegearbox in its maximum speed level. However, these types of gears4|P a g eV I J A Y K A D I R
AUTO AND COMPONENT DESIGN MSP5003UNIVERSITY OF BOLTONare difficult tomanufacture due to the increased difficulty andcomplexity in the time, shape, and cost of the involved individualparts[ CITATION Par08 \l 16393 ]DESIGNING GEARBOX PROCESSSpecifications of product’s design:the production or manufacture ofthese gearbox products involve the development of steps or the firstdevelopment of an imagination to the engineers to be involved.These engineers would then turn the concept of these imaginationsinto engineering files and drawings that depict the plan ofmanufacturing the design. Use of PDS, therefore, would allowelimination of unnecessary delay and checklist. The communicationinability to pass on an idea would make the eventual design looksimilar to previous designs as well as the review cycle to make theapproval for the incoming step. Using the PDS procedure can bedeveloped only if the gaolsof the design are stated clearly. In PDS,the goals involved have relations to one another, therefore, there isused for rating. Another essential step is the writing of engineeringspecifications[ CITATION Gen16 \l 1033 ].One appropriate way that the goal of the design can be achieved isby coming up with numerous design attributes. These attributes arethen rated depending on the engineering goals with specificationsguiding both designers and engineers. The end product couldproduce different results due to the varying inputs in design. Themain purpose is to make the team of designers understand the goalsof the design in the imagined process. One way of achieving this is bynoting down specifications required by engineers with the help ofengineering design tools such as CAD software. This software allowscommencing with the initial process of production. Physical conceptscan easily be used by engineers in coming up with hand sketches.5|P a g eV I J A Y K A D I R
AUTO AND COMPONENT DESIGN MSP5003UNIVERSITY OF BOLTONThe final 3D diagram could henceforth be developed by 3D CADsoftware that optimizes specific model parts. Better knowledge ofthe materials required for major purposes and the process ofmanufacturing that satisfies the design of required gearbox design isalso facilitated by the software. Selection of material, as well as theprocess of manufacturing, have to sync with the requirements of thedesign. Use of PDS design allows various volumes of production. Theneeds of the customers are therefore identified early enoughallowing their independence in the implementation of the finaldesign[ CITATION Gki16 \l 1033 ].CALCULATION:GEAR RATIO:this ratio has it the definition as direct measurement ratio ofdepicted speeds of rotation of any interlocking gears.Overall, in the start,there are two gears that include the drive gear that directly obtains more forceof rotation output by the engine having the larger size than the driven gear.The last gear has a higher turn speed and it opposite the direction of the firstgear. This brings out the formula;Gear ratio=T2/T1T1= total teeth number of the first gear.T2= total teeth number of the second gear.Determination of the basic ratio in gears involves the use of at least twoengaged gears that is the gear train. Most cases involve the first gear being thedrive gear that has an attachment to motor shaft while the second gear is thedriven gear that ah an attachment to the load shaft. In this project, the plan isto design a gearbox of 5-speed specification meaning there is a possibility ofusing many gears between the mentioned two types. These many gears wouldfacilitate power transmission. Ideal gears are the name of the intermediategears in between the two. Determining the gear ratio involves proper meshingthat facilitates proper constant construct as one gear turns the other[ CITATIONBos13 \l 1033 ]. A comparison of the teeth number is another method thatsimpler to use in finding the gear ratio in any two gears that interlock. Onemore way of achieving this is by manual counting of the teeth of gears6|P a g eV I J A Y K A D I R
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