DAMBI DOLLO UNIVERSITY

Collage Of Engineering and Technology

Department Of Mechanical Engineering
MACHINE DESIGN PROJECT II (MENG 5181)
title: design and analysis of a two – stage reduction gear box

STUDENT NO NAME OF THE STUDENT ID. NO

1 BEZABIH KASSIE 158/19

2 ABRHAM TESHALE 056/19

3 ZIAD TAHA

COURSE CODE: (MENG 5181)

BACHELOR SCIENCE MECHANICAL ENGINEERING (MANUFACTURING EXTREME)

DAMBI DOLLO, OROMIA, ETHIOPIA

SUBMISION DATE:
 DECLARATION

We, the undersigned declare that the project report entitled “DESIGN AND ANALYSIS OF A
TWO STAGE REDUCTION GEARBOX” has been carried out and submitted in partial
fulfillment of the requirements for the Bachelor of Technology in Mechanical Engineering at

Dambi Dollo University Institute of Engineering & Technology.

 ACKNOWLEDGEMENT

First of all, we would like to thank the Almighty of God for giving the strength to prepare this
design project. Secondly, we would like to express our sincere appreciation and special gratitude
to MR. Geleta Yadeta because he guides through out the project period which is very essential
for our future designing tasks. And also, we would like to express our great thank to Dambi
Dollo University as well as text book reference owners. The last but not the least we would like
to express our sincere appreciation for all individual who invested their time, energy and
resources to help us.
 Abstract
All-Terrain Vehicle is an Off-Road vehicle that has the ability to drive on any terrain without
any difficulty. These vehicles are designed to sustain any sort of extreme loads that act during
off road driving. All-Terrain Vehicles are fitted with large tires with grooves for better traction
on slippery terrains, high ground clearance to avoid obstacles, and usually designed with high
torque rather than speed. As compared to commercial vehicles, these vehicles are designed to
be stronger and more durable. These vehicles are vastly used in Deserts. Machine Engineering
Design of Gears, Shafts, Gearbox Casing, bearing selection, Vibrations caused due to the
Engine. These analytical designs have been validated through the help of CAD and FEA
software like Solid Works and ANSYS. Various Analysis like Structural, Repeated loads and
Computational Fluid Dynamics (CFD) have been performed to study the behavior of
components and oil flow during operations. The design is also finalized with the fits required
for assembly and the final product is expected to be efficient, light weight, compact and long
lasting than the other Gear boxes being used today.
 CHAPTER 1

1. INTRODUCTION
1.1 BACKGROUND
1.2 GEARBOX
A Gearbox is a device that used for transmitting power from the Power source
to the output shaft. A gearbox has a set of gears that are enclosed in a casing.
The gears are mounted on shafts which rotate freely about their axis. The
gears are fixed on the shafts by Fits or by a key. These shafts are made to
rotate freely on a support called casing. Bearings are tightly fit between the
shafts and the casing. Today’s cars have various sets of gears which give
different speeds and torque on different Gears. A Gearbox is necessary
because it is impractical to directly connect the input source to the output
shaft. The power source may not have enough torque to bear the whole load at
once. This will put a load on the power source which may cause overheating,
more fuel consumption or even failure of the components. Gearbox gives
leverage to the power source by enhancing the torque at initial gears and then
delivering high speeds at final stages. This reduces the capacity of the power
source required and hence less fuel consumption. Each Gearbox has its own
set of Gear ratios that can be selected by the driver or just one set of universal
Gear Ratio that will work with the help of a Torque converter or a
Continuously Variable Transmission Major components include gears,
Casing, Shafts, and Bearing.
 Figure 1.1: A Gearbox contain various Gear Ratios. [5]

1.3. REDUCTION GEARBOX:

A reduction gearbox is a device by which an input speed can be lowered for a

requirement of slower output speed, with same or more output torque. Reduction gear
assembly consists of a set of rotating gears connected to an output shaft. The high-speed
incoming motion from the wheel work is transmitted to the set of rotating gears, wherein
the motion or torque is changed. The number of gears used in the reduction gear
assembly depends on the output speed requirement of the application. The reduction gear
assembly is usually known as reduction gear box. Depending on the Output speed
required, the reduction may have single stage or two stage reduction.

1.3.1 Types of Reduction Gearbox

There are mainly two types of reduction gears:

• Single reduction gear

• Double reduction gear

Single Reduction Gear:

This arrangement consists of only one pair of gears. The reduction gear box
consists of ports through which the propeller shaft and engine shaft enters the assembly.
A small gear known as a pinion is driven by the incoming engine shaft. The pinion
directly drives a large gear mounted on the propeller shaft. The speed is adjusted by
making the ratio of the speed reduction to the diameter of pinion and gear proportional.
Generally, a single gear assembly has a gear double the size of a pinion.

1.3.2 PROBLEM STATEMENT

There are four principal shortcomings identified in the conventional gearbox design.
1)Weight- Too high
2) Compactness- Too low
3) Poor compatibility with the Briggs and Stratton, engine used at Baja event.
4) Low Torque output
 1.4 OBJECTIVES
1. To design and optimize reversal gearbox for all-terrain vehicle.
2. To reduce the heavy weight of the gearbox comprising of reversal system
in vehicles such as auto rickshaw, wheelchairs.
3. To reduce the reduction ratio of the gearbox in reverse system.
4. To reduce the cost of the the gearbox by using efficient materials.
5. To reduce the space required for the gearbox by designing an integrated
design model with respect to the other components in the assembly of the
vehicle.

1.4.1 SPECIFIC OBJECTIVES

 To determine the required reduction ratio based on the application
requirements.
 To select the appropriate gear types for each stage based on load capacity,
noise, and space constraints.
 To calculate gear ratio for each stage to achieve the desired overall reduction
ratio.
 To size gears based on torque and speed requirements, considering factors like
material strength, tooth, profile, and gear tooth contact ratio.

1.4.2 DESIGN METHODOLOGY

1. Requirements analysis
2. Conceptual design
3. Gear sizing and selection
4. Shaft design
5. housing design
6. lubrication and cooling
7. analysis and simulation
8. prototype development and testing
9. manufacturing and production
 10. installation and maintenance

1.4.3 SCOPE
1. Designing the gearbox to meet specific application requirements, such as desired
out put speed, torque, and other specification.
2. Selecting appropriate gear types, gear ratio, and sizes for each stage to achieve the
desired overall reduction.
3. Designing shafts and selecting bearings to transmit power between gears and
support the gearbox.
4. Performing stress analysis and dynamic analysis to ensure the gear box can handle
applied loads and operate smoothly.
5. Optimizing the design to minimize weight, size, and losses.
6. Determining lubrication and cooling requirements for proper operation and
longevity of the gearbox.
7. Preparing detailed manufacturing drawings and assembling the gearbox
components with precision.
8. Conducting performance tests to validate the gearbox’s design and functionality.
The Gearbox designed is lightweight, compact and gives more performance than the
present Reduction Gearboxes. However, there still scope for better and more precise
design in the following areas.
For this Reduction Gearbox, the differential should be connected externally through a
chain drive. This will still make the power train assembly little complicated.
Assembling the Differential inside the Gearbox itself will make the Power train
assembly simpler.

1.4.4 LIMITATION
 Complexity: designing and analyzing a two-stage reduction gearbox can be
complex, requiring expertise in mechanical engineering and specialized
software tools.
  Material limitation
 Cost constraints
 Manufacturing limitation
 Accuracy of analysis
 External factors
 Time constraints

CHAPTER 2
2.LITERATURE REVIEW

Design and analysis of two stage reduction of gearbox for all terrain vehicles
(OCT-2010) [1] .The parameters such as various road resistance ,air resistance, gradient
resistance etc. can affect the reduction ratio of gearbox. Design and development of trans
system for an ATV(May-2017) [2] To increase the efficiency with respective materials
and to achieve required reduction ratio with constant and continuous power transmission.
Design of reverse gear mechanism in two-wheeler for physically challenged person
(JULY-2016) [3] We studied reversed mechanism which consists of 3 shafts with keyway
cutting and four Spur gear mechanism shifted from R-L moves in forward direction and
L-R reverse direction for physically challenged person. Design and manufacturing of 2-
stage speed reduce for BAJAATV(OCT.-2017) [4] The parameters such as various road
resistance, air resistance, gradient resistance etc. can affect the reduction ratio of gearbox.
The Volvo Group [1] introduced a concept of Automatic Transmissions. It is discussed
that Manual Gearboxes are complicated in design and is difficult for the users to drive the
vehicle. Usage of so many components in the manual gearbox also reduced the efficiency
and the clutch plates had to be replaced periodically. The company stated that it is
difficult to implement manual gearbox in smaller vehicles.
HubvanDoorne of DAF [2] has developed the concept of Continuously Variable
Transmission (CVT). They have studied the concept briefly which was introduced by
Leonardo Da Vinci in 14090s.They have studied the concept and its flaws discovered
through 1900s and have manufactured a CVT that was implemented in cars. This resulted
in the new age of Automatic Transmissions. CVTs were first tested in Volvo cars.
Willis, Christopher Ryan [3] (VTechWorks-79677) have developed a CVT design
that can be tuned to a range of Reduction ratios. Such CVTs can be tuned and can be used
on any vehicle that can accommodate space for CVT. They have explained that such
CVTs still need a reduction gearbox with a fixed reduction gear ratio.
 Polaris Automobile [4] has successfully implemented CVT coupled with
Reduction Gearbox. They have stated that the power train in their ATVs is very
complicated and have studied the various complications caused due to the reduction
gearbox including Noise, Vibration and the Noise produced.
John M. Hawkins [5] simplified the design of a gearbox and made it more
compact for usage in low power vehicles like Mopeds and Forklifts. He even analyzed
the current flaws in reduction gearbox which were either reduced or nullified in his
design. His design was so compact that it is being used in Helicopters to increase the
torque which has reduced the startup time of the rotors.
Ralph Taggert [8] made a detailed experimental study on ‘Forces that affect the
operation and efficiency of reduction Gearbox’ that contributes the complete information
about a single stage reduction gearbox that includes dimensions of the real time
gyroplane parts, the parts used in the Gearbox, assembly of individual components of the
Gearbox, Gearbox mounting, VT mounting and Differential mounting in Automobiles.
Sellgren, U.; Akerblom, M. [9] have done extensive studies on the gearbox to
study the origin of noise at high speeds. Noises in gearbox is a sign of inefficient
operation and faster wear of components. It has been observed that the origin of noises is
from improper meshing of gears in the assembly. This mostly happens due to not giving
proper clearances between gear train that cause either huge Backlash or interference
hence leading to faster wear.
Canonsburg [10] made a detailed study on ‘ANSYS Workbench’ that includes the
process of ANSYS workbench Project, Project schematic, Toolbox, Modal Analysis, and
Configuring ANSYS Workbench. ANSYS workbench users interface
Todd Grimm [11] made a study on ‘Experimental Analysis on Aluminum Alloys’
which includes the advantages of Aluminum Alloys, Heat treatment methods and their
outcomes.
Ramesh Banothu [12] worked on ‘Design and analysis of Gear Shaft’ in which he
concluded that Vibrations can be transmitted from the casing to the gears through the
gear shafts. He even concludes that the shafts are subjected to bending moments and
slight torsion when there are at least two gears mounted on one shaft.
Vilas Warudkar [13] from his study ‘Design and Optimization of 2-Stage
Reduction Gearbox’ has concluded the methodology to make a conventional Reduction
gearbox for Water pumps. This Gearbox did not use any alloys for materials and did not
consider vibrations or Thermal analysis inside the Gearbox.