EML 3005: Mechanical Design

Planetary Gear Train Fatigue Design for an Automatic Transmission

Nagaraj K. Arakere
Group Project 2 (17th Nov 2016 )
Group Design Project Presentations: Nov 29-Dec 6. Report due on or before Dec 6.
Automatic transmissions (Figure 1 shows a schematic of a 6-speed automatic automobile
transmission) use planetary gear trains for achieving different gear ratios between the input (from
the torque converter or fluid coupling) and the output shaft. This transmission uses 3 planetary
gear trains (P1, P2, P3) and 5 clutch packs (C1-C5 in the 2nd figure below) to achieve 6 forward
gear ratios and 1 reverse gear ratio.

Clutch'C1'

'C2'

'C3'

'C4'

!P2!

'C5'

!P1!

!P3!
Fig. 1 Schematic of an automatic transmission
1

The following videos are recommended for understanding the operation of an automatic
transmission.
2D animation
https://www.youtube.com/watch?v=Ugao6jTyM7k
3D animation
https://www.youtube.com/watch?v=u_y1S8C0Hmc
3D
https://www.youtube.com/watch?v=YYr1gx_FdkY
Allison Truck Auto tranny
https://www.youtube.com/watch?v=1ByVBBfEXWk
https://www.youtube.com/watch?v=v4AJ2BvUMG4

The basic equation for solving the output motion of any planetary gear train is (Eq. 13-32):

For our purposes, ! = ! = , ! = ! = (),

! = ! = . The train value is given by e.

e=

nR nC
nS nC

(1)

First Gear
First gear is achieved by applying clutches C1 and C5. In the video the first gear ratio is given as
3.10. This means 3.1 rotations of the input shaft will result in one rotation of the output shaft.
The output shaft is always the planet carrier, shown in red. The input and output shafts turn in the
same direction (clockwise looking into the left end).
When ring gear is fixed and sun gear is input, the planer carrier speed (output), the gear ratio for
this configutation is (refer to class notes)

mG1 = 1+

NR
d
NR
= 1+ R = 3.1 or
= 2.1
NS
dS
NS

(2)

NR and NS are the number of teeth on the ring and sun gears, respectively. The gear pitch
diameter is d. Because of geometry,

d R = d S + 2d P ; Hence, N R = N S + 2N P
(3)
Using (2) and (3) we get we get
2

N P = 0.55N S ; d P = 0.55d S
The following tooth numbers satisfy the conditions (not an unique solution):

N P = 31, N S = 56, N R = 118

This results in a gear ratio of 3.107 for first gear, since we must have integer number of teeth.

mG1 = 1+

NR
118
= 1+
= 3.107
NS
56

For one rotation of input gear (clockwise is negative) the output will rotate -1/3.107 = -0.3218
revolutions.

Second Gear
3

Second gear is achieved by applying clutches C1 and C4. This results in the 2nd planet carrier
spinning with the gear rato of 3.107 (same as in first gear) or will rotate 1/3.107 = 0.3218
revolutions for 1 revolution of input gear. The carrier of 2nd planetary system is connected to the
ring gear of 1st planetary, which will speed up the output shaft, resulting in a faster 2nd gear.

" 56 % " 31 %
e = $ '$
' = 0.4745 = Train value
# 31 & # 118 &
We re-use Eq(1) as follows (assume sun gear input speed is at 1 rpm)

0.4745 =

0.3218 nC
1 nC

Solving for planet carrier speed, we get

nC = 0.54; 2nd gear ratio = mG 2 = 1/ 0.54 = 1.851

This means for 1.851 rotations of the input gear the output shaft will rotate once.

Third Gear
Third gear is achieved by applying clutches C1 and C3. This results in the carrier of the 3rd
planetary rotating at 1/3.107 = 0.3218 revolutions for 1 revolution of input gear. The carrier of
3rd planetary system is connected to the ring gear of 2ndt planetary (same as 2nd gear). This will
result in the ring gear of the 1st planetary to spin at -0.54 rotations for -1 input shaft rotation
(same as 2nd gear). Further the carrier of the 2nd planetary is connected to the ring gear of the 1st
planetary. This will speed up the output shaft in two stages, resulting in a faster 3rd gear.
From 2nd gear we know that the ring gear (brown carrier) will rotate -0.54 revolutions for -1
rotation of input gear. Therefore

0.4745 =

0.54 nC
1 nC

Solving for planet carrier speed, we get

nC = 0.6880; 3rd gear ratio = mG3 = 1/ 0.6880 = 1.453

This means for 1.453 rotations of the input gear the output shaft will rotate once.

Fourth Gear
Fourth gear (direct drive or 1:1 gear ratio) is achieved by applying clutches C1 and C2. This
results in a direct lockup (ring and sun gears have to spin at the same speed) with input and
output speeds being same.

Fifth Gear (overdrive)

Fifth gear is achieved by applying clutches C2 and C3. Note that the blue shaft is NOT
connected to input, and its RPM is decided by the 2nd planetary whose carrier is rotating at input
speed. The ring gear of the 1st planetary is spinning at input speed. Input speed is taken to be -1
RPM (clockwise) as before.
Stage 1 calculation (2nd planetary)
From 2nd gear we know that the ring gear (brown carrier) will rotate at -0.54 RPM. Note that the
p

0.4745 =

0.3218 (1)
nS (1)

Solving for sun gear rpm, we get

nS = 2.429
This will be the input to the 1st planetary sun gear along with the ring gear rotating at input speed
of -1 rpm.

Stage 2 calculation (1st planetary)

Here the ring gear is rotating at -1 RPM and sun gear at -1.9694 rpm. We need to find the output
or planet carrier speed.

0.4745 =

1 nC
2.429 nC

Solving for planet carrier or output rpm, we get

nC = 1.46; 5th gear ratio = mG5 = 1/ 1.46 = 0.685

This means for 1.0 rotation of the input gear the output shaft will rotate 1.46 revolutions
(overdrive, or output shaft spins faster than input shaft).

Planetary Gear Design

This project involves designing a 5-speed automatic transmission gearbox. This project involves
designing the gears of only the first planetary gear train (P1), based on fatigue life, and
bending and contact stress requirements. P1 gears go through the most cycles since they are
loaded no matter which gear is engaged. Hence gears of P1 are the most critical componets in the
transmission. Assume they are SPUR gears, for simplicity.You will select a car out of the article
I have shown in class. You are required to write a detailed report detailing your gearbox design.
The design report must present, at a minimum, the following information:
Car selection, details such as weight, external dimensions, tire size, etc.
Engine details (HP, torque ratings)
7

Drag coefficient, car frontal area calculations, estimated top speed. The Car &
Driver article gives you drag forces measured in a wind tunnel. We can use that to
calibrate your wind drag calculations.
Equations used for calculating wind drag and rolling resistance, to calculate HP
required at various speeds.
Gear ratios selected for the 5-speed transmission, axle ratio selected. We will
ignore the 6th speed since top speed is achieved in 5th gear.
Duty cycle selected for the gearbox design. Explain why you selected the speed
and mileage requirements. Design the gearbox for at least 250,000 miles. Select a
fairly large number of miles at the top speed, to adequately load the gearbox.
Make sure, based on your calculated HP requirements, that the car can indeed
reach those speeds.
Explain reason behind selection of the base point used for equivalent load
calculations.
Show all calculations pertaining to calculating numer of teeth for sun gear, planet
gears and ring gear for P1. Remember that numer of teeth has to be an integer!

Fatigue Life Calculations

The SUN GEAR of P1 will experience the most number of fatigue cycles (since there are 3
gear meshes for it). The planet gears are idler gears and experience double sided loading and
may be more critical than the sun gear. Whichever gear has the largest face width will be the
design face width (other gears will have this face width). Details of the equivalent torque
calculations and Neq should be presented in detail. Clearly indicate the baseline condition chosen.
Units for all variables must be clearly indicated. A table such as shown below should be
included. See example posted.
Cycle

Gear
Ratio

Speed
(mph)

Miles

Hours
Spent

RPM
@Input
Shaft

HP
@
Input
Shaft

Torque
@ Input
Shaft
(In-lb)

Wt
@ P1
(Lb)

1
2
3
N
Discuss selection of gear material, heat treatment and finishing requirements.
A scaled line drawing (schematic) of the gearbox (P1) should be presented.

Summary of the gearbox design details should be presented in a tabular form, an example of which is given below.

Pitch Diameter, in
Number of Teeth
Normal Pressure Angle,
Pd, Diametral Pitch
Addendum, a, in (=1/Pd)
Dedendum, b, in (=1.25/Pd)
Qv, Quality factor
V, ft/min
Kv, Velocity factor
Sc (Contact fatigue strength, ksi)
St (Bending fatigue strength, ksi)
Sy (Yield strength, ksi)
Teq (Contact, in-lb)
Teq (Bending, in-lb)
HPeq (contact)
HPeq (bending)
Neq (Equivalent fatigue cycles)
Life required, from duty cycle (hours)
Wt (contact, lb)
Wt (bending, lb)
Wt (Max Torque considerations, lb)
YN (life factor for bending)
ZN (life factor for contact)
all (allowable bending stress, ksi)
c,all (allowable contact stress, ksi)
Fc (face width based on contact stress, in)
Fb (face width based on bending stress, in)
Fc,accel (Max Torque - contact stress, in)
Fb,accel (Max Torque - bending stress, in)
Fdesign (design face width, in)
bending (Use Fdesign, Teq-ben, ksi)
YN (= bending /St)
contact (Use Fdesign, Teq-con, ksi)
ZN (= contact /Sc)
FOS (bending = all /bending)
FOS (contact = c,all /contact)
Design Life (using Fdesign, contact, hours)
Design Life (using Fdesign, bending, hours)
Design Life (using Fdesign, contact, cycles)
Design Life (using Fdesign, bending, cycles)
Contact Ratio

Sun Gear

Planet
Gear

Ring Gear

Ns

NP

NR

N/A
N/A

N/A
N/A
N/A
N/A