Addis Ababa University

College of Technology and Built Environment

Machine Design Project II

Design and Analysis of 5 Speed Manual synchromesh Gearbox with Baulk ring

Submitted by:

1. Bisrat Engida UGR/7862/14

Submitted To:
Dr. Mulugeta H.

Jan 31, 2026

This project focuses on the complete design and analytical development of a mechanical gearbox
system intended for practical engineering application. The work was carried out by systematically
following standard machine design methodology, beginning with geometric analysis and
progressing through force analysis, stress evaluation, and shaft design calculations. Each
component was dimensioned based on theoretical calculations and verified through engineering
design principles to ensure structural integrity and functional reliability. Detailed technical
drawings were then generated from the finalized measurements to reflect accurate manufacturing
specifications. In addition to the primary transmission components, auxiliary elements such as the
gearbox housing, lubrication system, and key design were also incorporated to achieve a
comprehensive and realistic mechanical assembly. The project demonstrates the integration of
analytical design, practical constraints, and technical drafting into a single feasible gearbox model
suitable for educational and prototyping purposes.
Table of Contents
Introduction
Detailed Design
I. Geometry Analysis
II. Force Analysis
III. Stress Analysis (Spur and Helical Gears)
IV. Shaft Analysis
Bending Moment and Torsion
Von mises Stress
V. Bearing Selection
VI. Housing Design
VII. Spline Design
VIII. Lubrication Selection

Part and Assembly Drawing

Conclusion

References
Introduction
Gearboxes are essential mechanical devices widely used in industrial machinery, automotive
systems, and power transmission applications to regulate speed, torque, and rotational direction
according to operational needs. The effectiveness of a gearbox depends heavily on accurate design,
material selection, load analysis, and proper integration of supporting components. This project
was undertaken with the intention of developing a complete gearbox design while strengthening
the understanding of mechanical design methodology and real-world engineering practices.

The design process followed a structured and sequential engineering approach. It began with
geometric analysis, where gear dimensions, pitch diameters, center distances, and transmission
ratios were established to satisfy performance requirements. Following this, force analysis was
conducted to identify tangential, radial, and axial loads acting on the gear teeth and shafts. Stress
analysis was then performed using established mechanical design theories to confirm that all
components could withstand operational forces within safe limits. Shaft design formed a critical
stage of the project, ensuring adequate strength, stiffness, and reliability under combined loading
conditions.

Once analytical verification was completed, detailed technical drawings were prepared based on
the calculated measurements, enabling a clear translation from theoretical design to
manufacturable specifications. The project also extended beyond the core gear train by including
the design of the gearbox housing for alignment and protection, lubrication planning to reduce
wear and heat generation, and key design for secure torque transmission between rotating
elements. This holistic design strategy ensured that the final gearbox was not only analytically
correct but also practical, maintainable, and aligned with real engineering applications.
Detailed Design
Part and Assembly Drawings
Conclusion
The gearbox design project successfully demonstrated the practical application of mechanical
engineering theories and systematic design procedures in developing a complete and functional
transmission system. By progressing methodically through geometric calculations, load
determination, stress verification, and shaft design, the project ensured that each mechanical
component satisfied both performance and safety requirements. The addition of housing structure,
lubrication considerations, and key design further enhanced the realism and completeness of the
system, transforming it from a simple gear arrangement into a comprehensive mechanical
assembly.

The preparation of detailed engineering drawings played a significant role in bridging the gap
between analytical work and physical manufacturing, highlighting the importance of precision and
clarity in technical communication. Throughout the project, emphasis was placed on feasibility,
reliability, and adherence to standard engineering practices, which contributed to producing a well-
balanced and technically credible gearbox model.

Overall, the project not only reinforced theoretical knowledge but also developed practical design
skills, analytical thinking, and an appreciation for integrated mechanical systems. The final
outcome represents a feasible and educational example of real-world gearbox design,
demonstrating competence in both engineering analysis and applied mechanical design principles.
 References
Bhandari, V. B. (2017). Design of Machine Elements (4th ed.). McGraw-Hill Education.

Budynas, R. G., & Nisbett, J. K. (2020). Shigley’s Mechanical Engineering Design (11th ed.).

McGraw-Hill Education.

Hamrock, B. J., Schmid, S. R., & Jacobson, B. O. (2014). Fundamentals of Machine Elements (3rd

ed.). CRC Press.

Juvinall, R. C., & Marshek, K. M. (2018). Fundamentals of Machine Component Design (6th ed.).

Wiley.

Khurmi, R. S., & Gupta, J. K. (2019). A Textbook of Machine Design (14th ed.). S. Chand

Publishing.

Norton, R. L. (2020). Machine Design: An Integrated Approach (6th ed.). Pearson Education.