DESIGN AND FABRICATION OF AUTOMATIC GEAR

TRANSMISSION SYSTEM (16 Pt Bold TNR)

PROJECT REPORT ( 14PT BOLD)

(12pt Bold)
Submitted
In Partial Fulfillment of
The Requirements for the Degree of

BACHELOR OF TECHNOLOGY
in
Mechanical Engineering

Under

Kakatiya University
Warangal.

by

V .Bhargava
B.Kranthi Kumar
Ch .Madhuri
V.Sasanka

Under the guidance of

Dr. N. Shyam Kumar, M.Tech, Ph.D

Professor

ESTD: 2009

Department of Mechanical Engineering

Warangal Institute of Technology & Science
Warangal - 506 342 (A.P)
2013
DESIGN AND FABRICATION OF AUTOMATIC GEAR
TRANSMISSION SYSTEM (16 Pt Bold TNR)

PROJECT REPORT ( 14PT BOLD)

(12pt Bold)
Submitted
In Partial Fulfillment of
The Requirements for the Degree of

BACHELOR OF TECHNOLOGY

In

Mechanical Engineering

Under

Kakatiya University
Warangal.

by
V .Bhargava (09474T0301)
B.Kranthi Kumar (09474T0312)
Ch .Madhuri (09474T0331)
V.Sasanka (09474T0371)

Under the guidance of

Dr. N. Shyam Kumar,

Kumar, M.Tech, Ph.D
Professor

ESTD: 2009

Department of Mechanical Engineering

Warangal Institute of Technology & Science
Warangal - 506 342 (A.P)
2013
 Department of Mechanical Engineering
Warangal Institute of Technology & Science
Oorugonda(V), Gudeppadu X Road, Athmakur(M)
Warangal - 506 342 (A.P)
ESTD: 2009

Date:

C E RT I F I C AT E

This is to certify that this is a bonafied report of the project “ DESIGN AND
FABRICATION OF AUTOMATIC GEAR TRANSMISSION SYSTEM”
SYSTEM carried out by K.
Vyasa Krishnaji (09474T0301) along with his project batch mates of final year B.Tech,
Mechanical Engineering (2009-2013) in partial fulfillment of the degree of B.Tech, in the
Warangal Institute of Technology & Science, Warangal.

(Dr. N. Shyam Kumar)

Project Guide

Chairman
Project Evaluation Committee

(Prof. G. Buchi Babu)

HEAD OF THE DEPARTMENT

// individual//
 Department of Mechanical Engineering
Warangal Institute of Technology & Science
Oorugonda(V), Gudeppadu X Road, Athmakur(M)
Warangal - 506 342 (A.P)
ESTD: 2009

Date:

C E RT I F I C AT E

This is to certify that this is a bonafied report of the projec t “ DESIGN AND
FABRICATION OF AUTOMATIC GEAR TRANSMISSION SYSTEM”
SYSTEM carried out by
B.KRANTIKUMAR(09474T0349),V.BHARGAVA(09474T0323),Ch.MADHURI(09474T033
8) and V.SASANKA (09474T0318) of final year B.Tech, Mechanical Engineering (2009-
2013) in partial fulfillment of the degree of B.Tech, in the Warangal Institute of Technology &
Science, Warangal.

(Dr. N. Shyam Kumar)

Project Guide

Chairman
Project Evaluation Committee

(Prof. G. Buchi Babu)

HEAD OF THE DEPARTMENT

// common to all batch – to be submitted to Dept,guide,library//

 ACKNOWLEDGEMENT
We express our deep gratitude and sincere thanks to our guide Sri. N. Shyam Kumar,

Professor in Mechanical Engineering Department for allocating his precious time to our

project work. We are deeply indebted to him for his logical guidance, support and

encouragement throughout the project whenever we approach him and bringing it to a

successful completion.

We express our gratefulness to Chairman and members of the project evaluation

committee for their critical evaluation and timely advices.

We owe our heartfelt thanks to Prof. N. Shyam Kumar, principal and Sri G. Buchi

Babu, Head of the Department of Mechanical Engineering for their kind co-operation.

We acknowledge the help of Sri L.Ravinder, Mechanic of Mechanical Engineering

department in the fabrication of our project.

We also thank all the supporting staff of workshop for their help in making our project

a success.

V.Bhargava

B.Kranthi Kumar

Ch.Madhuri

V.Sasanka
 CONTENTS

ABSTRACT

1. INTRODUCTION 1

1.1 Transmission System. 1

1.2 Functions of Transmission System. 1

1.3 Types of Transmission. 2

1.4 Functions of Various Components of Transmission System. 2

1.4.1 Driver Shaft.

1.4.2 Clutch.

1.4.3 Gear Box.

1.4.4 Gear Shift Lever.

1.4.5 Driven Shaft.

1.5 Necessity for a Clutch 4

1.6 Necessity for a Gear Box. 5

1.6.1 Types of Gear Box.

2. TWO WHEELER GEAR BOX 7

2.1 Construction of Two-Wheeler Gear Box. 7

2.2 Working of Two-Wheeler Gear Box. 8

2.3 Automatic Transmission. 10

2.3.1 Automatic Gear Transmission Using Planetary Gear Sets. 12

2.3.2 Automatic Gear Transmission Using Hydraulic System. 15

2.3.2.1 Torque Converter.

2.3.3 Manual valve Body Automatic Transmission.

2.3.4 Tiptronic Automatic Transmission.

2.4 Automatic Transmission Models 20

 2.5 Advantages and Drawbacks of Automatic Transmission 20

3. DESIGN AND IMPLEMENTATION OF AUTOMATIC GEAR 21

TRANSMISSION FOR THE TWO-WHEELER

3.1 Specifications Of The Engine Selected For Experimentation. 22

3.1.1 Specifications of engine selected for experimentation

3.1.2 D.C motor

3.2 Modification Done On the Engine. 23

3.3 Design of Pulley/ Belt Size. 23

3.4 Assembly 24

3.5 Experimental Setup 24

3.6 Plan for Automatic Gear Transmission System Implementation. 24

3.7 Strategy for Gear Shift. 24

3.8 Experimentation to Achieve Specific Speeds. 25

3.9 Speeds Selected For Gear Change. 26

3.10 Sequence for Obtaining the Gear Shift. 27

4. RESULTS AND CONCLUSIONS 28

4.1 Results. 28

4.2 Scope for Future Work. 29

REFERENCES 30
 ABSTRACT

For the vehicle to move forward the engine has to be connected to driving

wheels so as to propel the vehicle. The engine rotates at relatively high speeds, while

the wheels are required to turn at slower speeds. As such, the engine has to be geared

down permanently to the driving wheels in some fixed ratio. Moreover the torque

requirements of the vehicle vary as per the prevailing conditions. Gear box provides

different gear ratios between the engine and the driving wheels, to suit the varying road

conditions such as when climbing hills ,traversing rough road or sandy road or pulling

a load. The required gear shift for providing varying torque requirements can be

obtained either manually or automatically. In this project a new method is proposed to

obtain the gear shift automatically. This method has been studied and implemented.

Keywords: Gear Ratio, Transmission System

1 INTRODUCTION 14pt Times New Roman Bold

1.1 Transmission System 12pt Times New Roman Bold Double Space

The main purpose of a transmission system is to transmit the torque developed by

the engine to the road wheels, where it gives rise to a propulsive force between the
wheels and the road. Driver shaft, Clutch, Gear box (with gears of different gear ratios
in constant mesh), gear shift lever form the essential components of a transmission
system.
//Body Text 1.5 spacing 12pt Times New Roman Normal Both sides justified //

1.2 Functions of the Transmission System

The following are the functions to be performed by the transmission system:

1. To disconnect the engine from the driving wheels when starting the engine.

2. To connect the driving wheels smoothly and without shock to the engine, when

the engine is running.

3. To vary the leverage between the engine and the driving wheels, depending on the

resistance encountered by the vehicle.

4. To reduce the speed of the engine at the driving wheels in some fixed ratio.

5. To provide different gear ratios as per the torque requirement.

1.3 Functions of Various Components of Transmission System

1.3.1 Diver Shaft 12pt Times New Roman Italic

It is the shaft which is connected to the engine and supplies the power

generated in the engine to the driven wheels through the gear box.

1.3.2 Clutch

It enables the driver to disconnect the engine from the driving wheels.

However, its main function is to connect the engine, when it is running smoothly

and without shock to the driving wheels. The clutch is disengaged while changing

the gear ratio between the driver and the driven shafts.

Fig.1.1 Exploded View of The Clutch and Inside Parts

(Title Below Figure)

1.4 Experimentation to Achieve Specific Speeds

The experimental values of various speeds obtained at 1 st and 2nd gears at

different voltages is tabulated in Table 1.1.

 Table 1.1 Experimental Values of Voltages at various Speeds

(Table name above Table)

Gear Voltage Rpm at Rpm at o/p

motor shaft
1 20 110 15
30 188 25
40 285 40
50 360 55

REFERENCES

1. Dr.K.K .Ramalingam., “Automobile Engineering” ,SciTech Publications India Pvt .Ltd, 2006.

2. Bajaj Chetak Owners Manual – Model 1988.

3. Birch, Stuart. ,. “Audi takes automatic transmission from 15th century to 21st century”. Automotive

Engineering International Online. January.,2000.

4. Kluger, Michael A.,,”Gearing up for Automatic Transmission”, Technology Today. Summer

issue2000.

5. http://www.answers.com/main/ntquery?/automatictransmissions.

6. http://www.howstuffworks.com/automatictransmissionworking.htm.

General Instructions:

Page Layout:

A4 Executive Bond Paper on One side printing.

Chapter wise in New Page, with Page Separator.

25mm on Top , Bottom, Right Margin.

30mm Left Margin.

Body Text 1.5 Space, 12pt Times New Roman Normal Both sides Justified.