CHAPTER 1

INTRODUCTION

1.1. Introduction to Automobile Transmission

At the present day, automobile vehicles are widely used for transportation and
other purpose. The major system of the automobile vehicle are-engine, fuel, exhaust,
cooling, lubrication steering and suspension, breaking and transmission system.
Transmission is the essential part of the automobile vehicle for running. Vehicle
power train is the mechanism which transmits power from engine to the drive wheels.
In modern automobile, the power train comprises of a clutch, a gear box, universal
joints, propeller shaft, differential and axle extending to the wheels. The transmission
gears not only transmits power, but also they can increase or decrease speed and
torque of the engine.
The average engine would have enough power to operate a car without a
transmission provided the car operated on reasonably level roads and maintained
sufficient speed .When the car must be started from a standstill, or when attempting to
negotiate steep grades, the engine would not provide sufficient power and the car
would stall. Much less torque is required to move a car rolling on level ground than is
necessary to drive the same car up steep hill. To enable the engine to increase torque
to the drive line, it is obvious that a top multiplier transmission is needed. By using a
torque multiplier, it is possible to adapt the available power of the engine to meet
changing road and load conditions [14Hla].
In this thesis, the first and reverse speed gear design of gear box for 3C Diesel
engine is described. 3C Diesel engine which having the power ration 69 kW (93 hp) at
4200 rpm is used as the engine of Toyota Light Truck. This power transmission
system is composed of single plate clutch, transmission gear box, universal joint,
propeller shaft, rear axle gear box, drive axles and drive steel wheels. This gear box is
manual type and is designed for transmitting the power of engine to the rest of
transmission line. At the top gear, the transmission enables the car to run at the
maximum speed of 150 km/hr. Transmission system has two types of transmission.
They are namely manual transmission and automobile transmission, which are widely
used nowadays.
 2

The manual transmission is an assembly of gears that transmit the rotation and
torque of the crankshaft to the drove wheels. The manual transmission carries out
torque conversion in several drives. The driver has to shift gears using the gear shift
lever with hand or manually. In an automatic transmission model, the clutch and gear
shifting operation is done automatically to the best suit with the driving condition and
torque is converted continuously. These transmission systems are efficient,
convenient, easy to operate, durable and reliable, but they are relatively expensive to
manufacture and service compared to standard transmission system.
The transmission or gear box of an automobile can be controlled many
emergency cases that does not focus on vehicle movement by changing speed and
torque of the engine. Nevertheless, manual transmission type is used for so many cars
in various models and locations. In upgrading the technological knowledge, the first
step will be started from the simple and the basic one [12Khi].
The primary source of vibration and noise in a gear system is the transmission
error between meshing gears. Transmission error is a term used to describe or is the
defined as the different between the theoretical and actual positions between a pinion
(driving gear) and a driven gear.
Transmission error is usually due to two main factors. The first case has
manufacturing inaccuracy and mounting errors such as profile inaccuracies, spacing

error, and gear tooth run out. The second case is loaded transmission error, which is
similar in principle to the manufactured transmission error but takes into account
tooth bending deflection, shear displacement and contact deformation due to load.
Among the types of gear box noise, one of the most difficult to control is gear noise
generated at the tooth mesh frequency. Transmission error is considered to be one of
the main contributors to noise and vibration in a gear set. Tooth gears are used to
transmit the power with high velocity ratio. During this phase, they encounter high
stress at the point of contact.
Gear is most essential element of power transmission preferable for short distance.
It is very economical and very effective way of power transmission. A gear is a
machine element designed to transmit force and motion from one mechanical unit to
another. Gear failure can occur in various modes. Many modes of gear have been
identified, for example fatigue, wear or plastic deformation. Of these, one of the most
 3

common causes of gear failure is tooth bending fatigue. Two of the most common
modes of fatigue failure in gears are tooth bending fatigue and surface contact fatigue.
A pair of teeth in action is generally subjected to two types of cyclic stresses:
1. Contact stress causing contact fatigue
2. Bending stress inducing bending fatigue
Both these types of stresses may not attain their maximum values at the same
point of contact. However, combined action of both of them is the reason of failure of
gear tooth leading to fracture at the root of a tooth under bending and surface failure,
due to contact fatigue. The contact stress and bending stress are compared and plotted
for identical load conditions [17Khi].

1.2. Aim and Objectives

This thesis deals with the stress analysis of first and reverse gears in gear box
for Toyota Light Truck which has the following objectives.
1. To study the operation of vehicle transmission
2. To spread about the technologies of transmission
3. To improve the performance of the transmission system of automobile
4. To study the operation principle and theory of gears
5. To provide design evaluation and fabrication of power transmission
mechanism
6. To predict the contact stress and bending stress with analytical method
7. To compare ANSYS R17.0 software results with analytical results

1.3. Scope of Thesis

In this thesis, operation and main components of transmission gear box for
Toyota Light Truck are discussed. This is designed to drive at a speed of 150 km/hr.
3C Diesel engine which has the power rating 69 kW (93 hp) at 4200 rpm is used for
the Toyota Light Truck. The gear box is synchromesh type and has just five forward
speeds and one reverse speed of rear-wheel drive manual transmission. Design
calculation of first and reverse gears are presented. Comparing the results of the
different gained data. The main important parts of gears such as pitch circle, base
circle, addendum circle, circular pitch, module, face width and tooth depth are
designed. For gears, there are many types of gear failure but they can be classified
 4

into two general group. One is AGMA equation which can be used to calculate the
contact stress. The other is AGMA formula, which can be used to calculate the
bending stress. Finally, contact stress and bending stress on gear are analyzed by
using ANSYS software.

1.4. Implementation Program

The implementation program of this thesis is carried out by the following
procedures:
1. Studying on the types of the transmission system of automobile
2. Studying the power transmission mechanism of Toyota Light Truck.
3. Studying the theoretical background knowledge of the gear box.
4. Finding out the required data for the design calculation.
5. Emphasizing on the types of gears applied in transmission gear box and
calculating the loads on these first and reverse speed gear pairs .
6. Selecting the proper materials for these gears.
7. Studying the spur and helical gears and the type of failures.
8. Calculating the stress on the contact point and bending stress at the root of
tooth.
9. Simulation the stress by using ANSYS R17.0 software.
10. Comparisons between the analytical solution and simulation.

1.5. Outline of Thesis

The title of this thesis is stress analysis of first and reverse gears in gear box
for Toyota Light Truck. In this thesis, six chapters are composed. In Chapter one,
introduction to gear, aims and objectives, scope of thesis and implementation program
are described. Literature review and gear failure are expressed in Chapter two.
Chapter three is design consideration of gears for transmission gear box, AGMA
relations in contact and bending stress. Chapter four, develop the involute helical and
spur gears contact stress and simulation are discussed. Next, numerical analysis and
simulation of bending stress on the gears are presented in Chapter five. Finally,
conclusion and recommendations of this thesis are described in Chapter six.