ELEMENTS OF MECHANICAL ENGINEERING 1BESC104D

Module – 2
Engines: Introduction, petrol engine, diesel engines, Working of four Stroke engines, applications.
Insight into Future Mobility: Electric and Hybrid Vehicles, Components of Electric and Hybrid Vehicles.
Advantages and disadvantages of EVs and Hybrid vehicles.
Power Transmission systems: Classification of gears, simple & compound gear trains, concepts of
automatic and CVT transmission.
ENGINE:
A heat engine is a machine, which converts heat energy into mechanical energy. The combustion
of fuel such as coal, petrol, and diesel generates heat. This heat is supplied to a working substance at high
temperature. By the expansion of this substance in suitable machines, heat energy is converted into useful
work.
Heat engines can be further divided into two types:
(i) External combustion and (ii) internal combustion.

External combustion Engine: - In a steam engine the combustion of fuel takes place outside the
engine and the steam thus formed is used to run the engine. Thus, it is known as external combustion
engine.

Internal combustion Engine: - In the case of internal combustion engine, the combustion of fuel
takes place inside the engine cylinder itself.

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I C ENGINE:
An internal combustion engine (I C Engine) is a heat engine, which converts the heat energy
released by the combustion of the fuel taking place inside the engine cylinder into mechanical work.
The advantages of I C Engines compared to External combustion Engines are high efficiency, light
weight, compactness, easy starting, suitable for mobile applications and comparatively lower initial cost.

CLASSIFICATION OF IC ENGINES:
According to the type of fuel used:
a) Petrol engine - If the fuel used is petrol, the engine is called as petrol engine.
b) Diesel engine - If the fuel used is diesel, the engine is called as diesel engine.
c) Gas engine - gaseous fuels like bio-gas, natural gas, or liquefied petroleum gas (LPG), etc., are used as
fuels.
d) Bi-fuel (Bio-fuel) engine - these engines use a mixture of more than one fuel. For example, mixture of
diesel and natural gas, mixture of diesel and neem oil, etc.

According to the number of strokes per cycle:

a) 4-stroke engine - if the engine completes its working cycle in four different strokes of the piston, or
two revolutions of the crankshaft, it is called as 4-stroke engine.
b) 2-stroke engine - if the engine completes its working cycle in two different strokes of the piston, or
one revolution of the crankshaft, it is called as 2-stroke engine.

According to the method of ignition:

a) Spark Ignition (SI) engine - If the fuel is ignited by an electric spark generated by a spark plug, the
engine is called as spark ignition engine.
b) Compression Ignition (CI) engine - In these engines, the fuel ignites when it comes in contact with the
hot compressed air.

According to the cycle of combustion:

a) Otto cycle engine - If the combustion of fuel takes place at constant volume, the engine is called Otto
cycle engine.
b) Diesel cycle engine - combustion of fuel takes place at constant pressure.
c) Dual combustion cycle engine - combustion of fuel first takes place partially at constant volume, and
then at constant pressure.
According to the number of cylinders used:
a) Single cylinder engine - If the engine consists of only one cylinder, then it is called as single cylinder
engine.
b) Multi-cylinder engine - If the engine consists of more than one cylinder, then it is called as multi-
cylinder engine.

According to the arrangement of cylinders:

a) Vertical engine - If the cylinder is arranged in a vertical position, the engine is called vertical cylinder
engine.
b) Horizontal engine - cylinder is arranged in horizontal position.
c) Inline engine - cylinders are arranged in a line. Most trucks are of inline configuration.
d) Radial engine - cylinders are arranged along the circumference of a circle.

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e) V-engine - It is a combination of two inline engines equally set at an angle. Passenger vehicles have
V-type configuration.
f) Opposed type engine - cylinders are arranged opposite to each other.

According to the method of cooling:

a) Air cooled engine - If the heated cylinder walls (due to combustion of fuel) are cooled by circulating
air, the engine is called air cooled engine.
b) Water cooled engine - water is circulated through the jacket surrounding the healed cylinder walls.

According to their uses:

a) Stationary engine
b) Automobile engine
c) Marine engine
d) Aircraft engine, etc.

PARTS OF AN IC ENGINE:
The following are the main parts of an internal combustion engine.
1) Cylinder 2) Piston
3) Piston rings 4) Connecting rod
5) Crank 6) Crankshaft
7) Crankcase 8) Fly wheel
9) Valves

Cylinder:
It is the heart of an I C Engine, as the name indicates is a cylindrical shaped component in which
combustion of fuel takes place. The cylinder is usually made from gray cast iron or steel alloys in order
to withstand the high pressure and temperature generated inside the cylinder due to combustion of fuel.

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Piston:
The piston is a close fitting hollow cylindrical plunger moving to and fro in the cylinder. The power
developed by the combustion of the fuel is transmitted by the piston to the crankshaft through the
connecting rod.

Piston Rings:
The piston rings are the metallic rings inserted into the circumferential grooves provided at the top end of
the piston. These rings maintain a gas-tight joint between the piston and the cylinder while the piston is
reciprocating in the cylinder. They also help in conducting the heat from the piston to the cylinder.
Connecting Rod:
It is a link that connects the piston and the crankshaft by means of pin joints. It converts the rectilinear
motion of the piston into rotary motion of the crankshaft.

Crank:
The crank is a lever, with one of its end connected to the lower end of the connecting rod, while the
other end connected to the crankshaft.
Crankshaft:
The function of the crankshaft is to transform reciprocating motion into rotary motion. The crankshaft
transmits the power developed by the engine through the flywheel, clutch, transmission and differential
to drive (move) the vehicle. The crankshafts are made of carbon steel.

Crankcase:
The crankcase is the lower part of the cylinder block that encloses the crankshaft and provides a
reservoir for the lubricating oil.

Flywheel:
It is a heavy wheel mounted on the crankshaft of the engine to maintain uniform rotation of the
crankshaft.

Valves:
The valves are the devices which controls the flow of the intake and the exhaust gases to and from the
engine cylinder. They are also called poppet valves. These valves are operated by means of cams driven
by the crankshaft through a timing gear or chain.

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FOUR-STROKE PETROL ENGINE (4-S-P-E):-

A four-stroke petrol engine works on Otto cycle. Hence it is also called Otto cycle engine.
The charge used in a 4-Stroke petrol engine is a mixture of air and petrol, and is supplied by the
carburettor in suitable proportions. The charge is ignited by the spark generated by a spark plug, and for
this reason, petrol engines are also called Spark Ignition (SI) engines.

Fig: Otto cycle (P-V diagram)

Working:
In a 4-Stroke petrol engine, the working cycle is completed in four different strokes of the piston.

1) Suction stroke: At the beginning of the suction stroke, the piston is at the top dead centre (TDC), and
is about to move towards the bottom dead centre (BDC). At this instance, the inlet valve is opened and
the exhaust valve is closed. The downward movement of the piston produces suction (partial vacuum) in
the cylinder, due to which fresh charge of air and petrol mixture is drawn into the cylinder through the
inlet valve.
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When the piston reaches the BDC, the suction stroke ends and the inlet valve is closed. With this
stroke, the crankshaft rotates through 180° or half-revolution.
The energy required for the piston movement is taken from a battery. The suction of air takes
place at atmospheric pressure, and is represented by the line AB on p-v diagram.

2) Compression stroke: During the compression stroke, the piston moves from BDC to TDC. Both the
inlet and exhaust valves remain closed. As the piston moves upwards, the air-petrol mixture in the
cylinder gets compressed (squeezed), due to which the pressure and temperature of the mixture increases.
The compression process is adiabatic [Adiabatic - It is a process in which there is no heat transfer
from the system to the surroundings or vice-versa.] in nature and is shown by the curve BC on p-v
diagram. When the piston is about to reach the TDC, the spark plug initiates a spark that ignites the air-
petrol mixture. Combustion of fuel takes place at constant volume as shown by the line CD on p-v
diagram.
Since combustion of fuel takes place at constant volume, 4-Stroke petrol engines are also called
as constant volume cycle engines. With this stroke, the crankshaft rotates by another 180° or half
revolution. The energy required for the piston movement is taken from a battery.

3) Power stroke (Expansion stroke or Working stroke): During this stroke, both the valves will
remain closed. As the combustion of fuel takes place, the burnt gases expand and exert a large force on
the piston causing it to move rapidly from the TDC to BDC. The force (or power) is transmitted to the
crankshaft through the connecting rod.
As a result, the crankshaft rotates at high speeds. The crankshaft then transmits the power through
clutches, gears, chains, etc... To turn the wheels of the vehicle and cause it to move. The expansion of
gases is adiabatic in nature and is shown by the curve DE on p-v diagram.
Since the actual power or work is produced by the engine in this stroke, it is also called as power
stroke or working stroke. Also, expansion of gases occurs during this stroke, and hence the name
expansion stroke.

4) Exhaust stroke: Towards the end of the expansion stroke, the exhaust valve opens, while the inlet
valve remains closed. A part of the burnt gases due to their own expansion escapes out of the cylinder
through the exhaust valve.
This drop in pressure at constant volume inside the cylinder is represented by the line EB on p-v
diagram. The exhaust stroke begins when the piston starts moving from the BDC to TDC. The energy for
this stroke is supplied by the flywheel, which it had absorbed in the previous stroke. As the piston moves
upwards, it forces the remaining burnt gases to the atmosphere through the exhaust valve. The exhaust
taking place at atmospheric pressure is shown by the line BA on p-v diagram.
When the piston reaches the TDC, the exhaust valve closes and the working cycle is completed.
In the next cycle, the piston starts moving from TDC to BDC, the inlet valve opens allowing fresh charge
to enter into the cylinder, and the process continues. Thus it is clear that, the four different strokes or one
working cycle is completed when the crankshaft rotates through 720° or two revolutions.
Four-stroke petrol engines are commonly used in scooters, motor bikes, cars, large boats, etc.

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FOUR STROKE DIESEL ENGINE (4-S-D-E):-

A 4-stroke diesel engine works on Diesel cycle. Hence it is also called Diesel cycle engine. The
working principle is similar to that of 4-stroke petrol engine, except a fuel injector is used in place of
spark plug, and only air enters the cylinder during the suction stroke and gets compressed in the
compression stroke.

Fig: Diesel cycle (P-V diagram)

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Working:
1) Suction stroke: At the beginning of the suction stroke, the piston is at the top dead centre (TDC), and
is about to move towards the bottom dead centre (BDC). At this instance, the inlet valve is opened and
the exhaust valve is closed.
The downward movement of the piston produces suction (partial vacuum) in the cylinder, due to
which air from the atmosphere is drawn into the cylinder through the inlet valve. When the piston reaches
the BDC, the suction stroke ends and the inlet valve is closed. With this stroke, the crankshaft rotates
through 180° or half-revolution.
The energy required for the piston movement is taken from a battery. The suction of air takes
place at atmospheric pressure, and is represented by the line AB on p-v diagram.

2) Compression stroke: During the compression stroke, the piston moves from BDC to TDC. Both the
inlet and exhaust valves remain closed. As the piston moves upwards, the air in the cylinder gets
compressed (squeezed), due to which the pressure and temperature of the air increases.
The compression process is adiabatic in nature and is shown by the curve BC on p-v diagram. When the
piston is about to reach the TDC, a quantity of diesel is injected in the form of fine sprays into the hot
compressed air by a fuel injector.
Combustion of fuel takes place at constant pressure as shown by the line CD on p-v diagram.
Since combustion of fuel takes place at constant pressure, 4-Stroke diesel engines are also called as
constant pressure cycle engines.
With this stroke, the crankshaft rotates by another 180° or half revolution. The energy required
for the piston movement is taken from a battery. Since the heat of compression ignites the diesel injected
into the cylinder, diesel engines are also called as compression ignition engines.

3) Power stroke (Expansion stroke or Working stroke): During this stroke, both the valves will
remain closed. As the combustion of fuel takes place, the burnt gases expand and exert a large force on
the piston causing it to move rapidly from the TDC to BDC.
The force (or power) is transmitted to the crankshaft through the connecting rod. As a result, the
crankshaft rotates at high speeds. The crankshaft then transmits the power through clutches, gears, and
other transmission elements to turn the wheels of the vehicle and cause it to move. The expansion of
gases is adiabatic in nature and is shown by the curve DE on p-v diagram.

4) Exhaust stroke: During this stroke, the inlet valve remains closed and the exhaust valve opens. The
greater part of the burnt gases escapes because of their own expansion. The drop in pressure at constant
volume is represented by the vertical line EB.
The piston moves from bottom dead centre to top dead centre and pushes the remaining gases to
the atmosphere. When the piston reaches the top dead centre the exhaust valve closes and the cycle is
completed.

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Differences between Petrol and diesel engine (Differences between spark-ignition and Compression-
ignition engine):
Sl no Principle Petrol engine Diesel engine
( S I Engine) ( C I Engine)
1 Working cycle Works on Otto cycle Works on diesel cycle
2 Fuel used Petrol Diesel
3 Admission of the During the suction stroke itself the At the end of the compression
fuel petrol admitted to the cylinder with stroke the diesel is injected into
air the cylinder

4 Charge drawn Air and petrol mixture is drawn Only air is drawn during the
during the suction during the suction stroke suction stroke
stroke
5 Compression ratio Low compression ratio ranging High compression ratio ranging
from 7:1 to12:1 from 16:1 to 20:1
6 Ignition of the fuel Petrol is ignited by the sparkplug Diesel is ignited by compression
ignition or self-ignition
7 Engine speed High engine speeds of about 3000 Low engine speeds ranging from
rpm 500 to1500 rpm

8 Power output Because of the low compression Due to high compression ratio the
ratio power developed will be less power developed will be more

9 Thermal efficiency The thermal efficiency is less due The thermal efficiency is higher
to lower compression ratio due to high compression ratio

10 Noise and vibration Because of lower operating Because of higher operating

pressure the noise and vibrations pressure the noise and vibrations
are almost nil are high

11 Weight of the Weight of the engine is less Weight of the engine is more
engine
12 Initial cost Initial cost of the engine is less Initial cost of the engine is more

13 Operating fuel cost Operating fuel cost is more Operating fuel cost is less
because petrol is because diesel is
costly cheap
14 Maintenance cost Less Slightly higher
15 Starting of the The petrol engines can easily be The diesel engines are difficult to
engine started even in cold weather start in cold weather
16 Exhaust gas The exhaust pollution is more The exhaust gas
pollution pollution is less
17 Uses Used in scooter, motor cycle, cars Used in trucks, tractors, buses,
etc… heavy vehicles, etc….

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Insight into Future Mobility:
Electric Vehicles (EV):
An electric vehicle (EV) is one that operates on an electric motor, instead of an internal-combustion engine
that generates power by burning a mix of fuel and gases. Electric Vehicles (EV’s) include road and rail
vehicles, surface and underwater vessels, electric aircraft and electric spacecraft. Though the concept of
electric vehicles has been around for a long time, it has drawn a considerable amount of interest in the past
decade amid a rising carbon footprint and other environmental impacts of fuel-based vehicles. An electric
vehicle may be powered through a collector system by electricity from off-vehicle sources, or may be self-
contained with a battery, solar panels, fuel cells or an electric generator to convert fuel to electricity.
EV is defined as a vehicle that can be powered by an electric motor that draws electricity from a
battery and is capable of being charged from an external source.
Types of Electric Vehicles:
 Battery Electric Vehicles (BEVs)
 Hybrid Electric Vehicles (HEVs)
 Plug-in Hybrid Electric Vehicles (PHEVs)
 Fuel Cell Electric Vehicles (FCEVs)

Battery Electric Vehicles (BEVs):

It is also known all electric vehicles, instead of internal combustion engine runs on battery power. The
electricity use to drive a vehicle is stored in large battery pack, which can be charge plug in into by large
electricity grid with different level of charging method. The charge battery pack provides power to motor

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to run electric vehicle.

Main Parts of Battery Electric Vehicles are

 Electric Motor
 Inverter
 Control Module
 Battery

Working principle of Battery Electric Vehicles:

 Working principle of battery electric vehicle is very simple

 The battery electric vehicles are simple in construction and operation
 The power for electric motor is converted DC battery to AC
 As accelerator press the signal will send to controller
 The controller change the vehicle speed by changing frequency of AC power from the inverter to
motor
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 Then the motor gets connects to leads run the vehicle

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 If the break press electric car decelerates
 The motor becomes alternator to produces power and send back battery
 These are do not produce any green house gases
 Do not create any noise and beneficial to environment

Advantages of BEV:
 No emission: The biggest advantage of an electric vehicle is its green credential. Electric cars are 100
percent eco-friendly as they run on electrically powered engines. It does not emit toxic gases or smoke
in the environment as it runs on a clean energy source.
 Not dependent on oil: Electric cars are entirely charged by the electricity you provide, meaning you
don’t need to buy any fuel ever again. Driving fuel-based cars can burden a in your pocket as prices of
fuel have gone all-time high.
 Cost effective: Earlier, owning an electric car would cost a bomb. But with more technological
advancements, both cost and maintenance have gone down.
 Low maintenance: Electric cars run on electrically powered engines, and hence there is no need to
lubricate the engines, anything related to the combustion engine or a ton of maintenance tasks that are
usually associated with a fuel engine.
 Reduced noise pollution: Electric cars put a curb on noise pollution as they are much quieter. Electric
motors are capable of providing smooth drive with higher acceleration over longer distances.
 Easy driving: In the world of automobiles, electric cars have the simplest driving method.
Commercial electric cars come with a transmission comprising of only one really long gear and also
don’t suffer from the stalling problem as petrol cars do.

Disadvantages of BEV:
 Recharging points: Electric fuelling stations are still in the development stages. Not a lot of places
you go to on a daily basis will have electric fuelling stations for your vehicle, meaning that if you’reon
a long trip or decide to visit family in a rural or suburban area and run out of charge, it may be harder
to find a charging station.
 Short driving range and speed: Electric cars are limited byrange and speed. Most of these cars have
a range of about 50-100 miles and need to be recharged again. You just can’t use them for long
journeys as of now, although it is expected to improve in the future.
 Longer recharge time: While it takes a couple of minutes to fuel your gasoline-powered car, an
electric car takes about 4-6 hours and sometimes even a day to get fully charged.
 High price: As EVs are very new, you may be surprised when you take a look at the price for EVs.

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Hybrid Electric Vehicles (HEVs):
What is a hybrid? A hybrid vehicle combines any two power (energy) sources. Possible combinations include
diesel/electric, gasoline/fly wheel, and fuel cell (FC)/battery. Typically, one energy source is storage, and the
other is conversion of a fuel to energy. The combination of two power sources may support two separate
propulsion systems. Thus to be a True hybrid, the vehicle must have at least two modes of propulsion. For
example, a truck that uses a diesel to drive a generator, which in turn drives several electrical motors for all-
wheel drive, is not a hybrid. But if the truck has electrical energy storage to provide a second mode, which is
electrical assists, then it is a hybrid Vehicle. These two power sources may be paired in series, meaning that
the gas engine charges the batteries of an electric motor that powers the car, or in parallel, with both
mechanisms driving the car directly.
The hybrid electric vehicles are a combination of IC engine with an electric motor. Hybrid electric vehicles
are also known as series hybrid, parallel hybrid and series-parallel hybrid vehicles.
In hybrid electric vehicles engines gets energy from fuel and motor receives electricity from battery. The
transmission takes place simultaneously from engine and motor, which drives the wheels of vehicles. This
combination helps increases the efficiency of engine. The hybrid electric vehicles cannot be plug in to charge
the battery instead the battery charge by regenerative breaking system and internal combustion engine. The
regenerative breaking system use to stop the vehicles stores the kinetic energy and charge battery with
alternator. This stored energy from IC engine and regenerative breaking system is used to accelerate the
vehicle.
Main Parts of Hybrid Electric Vehicles are
 IC Engine
 Electric Motor
 Battery pack with Controller and Inverter
 Fuel Tank
 Power Electronics system

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Working principle of hybrid electric vehicles:
Fuel tank supply fuel to engine to produce power like a regular car and batteries runs an electric motor. Both
the engine and motor power transmission drives the vehicle simultaneously. This is tremendous advantages
like urban regions and reduces fuel consumption as engine stay off during idling period such as in trafficjams.
This feature also reduces green house gases emission. When highest speed is needed hybrid vehicles switch to
IC engine mode and both together can improve the performance of vehicles and also increase the mileage.
A hybrid electric vehicle cannot be plugged in for the battery to charge. The battery is charged with the help
of regenerative braking and by the internal combustion engine. It helps to transform kinetic energy produced
by the moving car into electrical energy stored back in the batteries.
The electric motor powers the vehicle as well as resists its motion. When you apply the brakes to slow down,
this resistance slows down the wheel and simultaneously recharges the batteries.
Types of Hybrid Electric Vehicles:
Series Hybrid Electric Vehicles:

In this type of hybrid eclectic vehicle, the internal combustion engine drives electric generator and not the
wheels of vehicle. The generator not only charges the battery and it also powers the motor to drives
vehicles. It operates when the fuel tank sends fuel/gas to the engine, which it then uses to power itself and
the generator. The generator converts the mechanical to electrical and charges the battery via the charger.
The battery pack takes the energy received from the engine and sends it to the controllers, which control
the voltage sent to the motors. The inverter circuit is included depending on the motor type present in the
vehicle. Finally, the powered motor is connected to the wheels via a reduction gear fordrivingthe vehicle.
The engine is responsible only for charging the battery so the vehicle can move with or without the engine
running. And the motor is responsible for the acceleration of the vehicle. Typically there is no mechanical
connection between an engine and the wheels of the vehicle. This system operates at the most efficient and
desired speed and load.
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Parallel Hybrid Electric Vehicles:
In the parallel hybrid mode, both the engine and the electric motor are coupled to the wheels to propel the
vehicle. The engine supplies its power mechanically to the wheels (like in a conventional vehicle), and the
engine is assisted by an electric motor if necessary. The battery in the vehicle will charge when the motor
works as a generator. Some of the advantages of the parallel mode operation include a reduced traction motor
size, no need for a generator, and the elimination of efficiency losses in multiple power conversion processes
between the electric machines and the battery.

Series-Parallel Hybrid Electric Vehicles:

The vehicle can be powered by the IC engine working alone, the electric motor by itself, or by both energy
converters working together. Power distribution between the engine and motor is designed so that the engine
can run in its optimum operating range as much as possible.

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Advantages of HEV:
 Environmental friendly: One of the biggest advantages of a hybrid car over a fuel powered car is
that it runs cleaner and has better gas mileage, which makes it environmentally friendly.
 Regenerative breaking system to charge battery: Each time you apply the brake while driving a
hybrid vehicle, it helps you recharge your battery a little. An internal mechanism kicks in that
captures the energy released and uses it to charge the battery, which in turn eliminates the amount of
time and need for stopping to recharge the battery periodically.
 Assistance from electric motor: The electric motor assists the internal combustion engine in case of
accelerating, passing or climbing a hill.
 Smaller engines: The gasoline engines used in hybrid cars are usually small, light, and highly
efficient as they don’t have to power the car alone.
 Higher resale value: With a continuous increase in the price of fuels, more and more people are
turning towards hybrid cars. The result is that these green vehicles have started commanding higher
than average resale values.
 Less dependence on fissile fuels: A Hybrid car is much cleaner and requires less fuel to run, which
means fewer emissions and less dependence on fossil fuels. This, in turn, also helps to reduce the
price of fuel in the domestic market.

Disadvantages of HEV:
 Less power: Hybrid cars have twin-powered engines. The fuel engine, which is the primary source
of power, is much smaller as compared to what you get in single-engine powered cars, while the
electric motor is of low power. The combined power of both is often less than that of a gas-powered
engine. It is therefore suited for city driving and not for speed and acceleration.
 Expensive: The biggest drawback of having a hybrid car is that it can burden more in your pocket.
Hybrid cars are comparatively more expensive than regular petrol cars
 Difficult handle: A hybrid car houses a gasoline-powered engine, a lighter electric engine, and a
pack of powerful batteries. This adds weight and eats up the extra space in the car. Extra weight
results in fuel inefficiency and manufacturers cut down weight, which has resulted in motor and
battery downsizing and less support in the suspension and body.
 Battery replacement cost is more: The battery replacement in hybrid vehicles is currently rare.
However, if a battery needs to be replaced, it need more cost.

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Power Transmission systems:
Power Transmission systems are methods and mechanisms used to transfer mechanical power from the
source (like an engine or motor) to the point where it is used (such as wheels, tools, or machinery). They are
essential in automobiles, industrial machines, and various engineering applications.
Types of Power Transmission Systems
1. Mechanical Power Transmission
 Uses physical elements to transmit power.
 Examples:
1. Belt drives (flat belt, V-belt, timing belt)
2. Chain drives (roller chain, silent chain)
3. Gear drives (spur, helical, bevel, worm gears)
4. Shafts & couplings
2. Electrical Power Transmission
 Transmits power in the form of electricity.
 Examples:
1. AC transmission (long distance power grids)
2. DC transmission (HVDC systems)
3. Hydraulic Power Transmission
 Uses pressurized fluid to transmit power.
 Examples: Hydraulic brakes, hydraulic presses, excavators.
4. Pneumatic Power Transmission
 Uses compressed air to transmit power.
 Examples: Pneumatic drills, air brakes, automation systems.
Gears:
A gear is a rotating machine element with teeth that mesh with another toothed part to transmit torque and
motion. Gears change the speed, torque, and direction of power between shafts.
Functions of Gears
 Transmit power from one shaft to another.
 Change speed (increase or decrease).
 Multiply or reduce torque.
 Change direction of motion.
Classification of gears:
1. Parallel Axis Gears
These gears have axes that are parallel to each other.

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 Spur Gears: The most common type, they have teeth that are straight and perpendicular to the axis of
the gear, providing smooth motion.
 Helical Gears: Have teeth that are cut at an angle to the axis, allowing for smoother and quieter
operation than spur gears, especially at higher speeds.
 Herringbone Gears (Double Helical): Consist of two sets of helical teeth with opposite helix angles
on the same gear, which helps to eliminate axial thrust.
 Internal Gears: Have their teeth on the inside surface of a ring.
2. Intersecting Axis Gears
The shafts of these gears cross each other, usually at a 90-degree angle.
 Bevel Gears: Transmit power and motion between shafts that are at an angle to each other.
1. Straight Bevel Gears: Simple bevel gears with straight teeth.
2. Spiral Bevel Gears: Similar to helical gears, but with teeth that are curved and angled for
smoother engagement.
3. Miter Gears: A special type of bevel gear where the bevel angle is 45 degrees.
3. Nonparallel and Nonintersecting Axis Gears
The axes of these gears are neither parallel nor intersecting.
1. Worm Gears: Consist of a "worm" (a screw-like gear) and a "worm wheel" (a gear that meshes with
the worm). They have a sliding action and offer high gear reduction, but are less efficient than parallel
or intersecting gears.
2. Hypoid Gears: A type of nonparallel, nonintersecting gear with a curved tooth design, allowing for a
much larger reduction ratio and more compact design, often used in automotive rear axles.
3. Screw Gears (Crossed Helical): Similar to helical gears, but their axes are not parallel.

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INTRODCTION TO MECHANICAL ENGINEERING 1BESC104D
Gear Trains:
A gear train is a mechanical system of two or more meshed gears that transmit rotational motion and torque
between shafts, changing speed, direction, or torque.
Functions of gear trains:
 Speed Change: Gear trains can reduce or increase rotational speed.
 Torque Change: They can also increase or decrease torque.
 Directional Change: The arrangement of gears can change the direction of rotation.
Types of Gear Trains
 Simple Gear Train: One gear on each shaft, transmitting power from one shaft to another.
 Compound Gear Train: Some shafts have more than one gear fixed to them, allowing for larger
changes in speed and torque over a smaller space.
 Reverted Gear Train: The input and output shafts are collinear (on the same axis).
 Planetary (Epicyclic) Gear Train: Features a more complex arrangement where one gear orbits
another, allowing for high gear ratios and compact designs.
Simple Gear Train:
A simple gear train is a series of gears, with only one gear on each shaft, which transmit rotational motion
between parallel shafts. The input gear is the driver, and the output gear is the driven gear; intermediate gears,
or idlers, transmit power but do not affect the overall gear ratio. These trains are used for speed reduction or
increase, with the speed ratio determined by the number of teeth on the driving and driven gears.

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INTRODCTION TO MECHANICAL ENGINEERING 1BESC104D
Velocity Ratio
The velocity ratio (VR), also known as the gear ratio, of a simple gear train is the ratio of the angular
speed of the first gear to the last gear.
The formula for the velocity ratio of a simple gear train is:

Where:
N is the angular speed (rpm).
T is the number of teeth.
Applications
 Watches and clocks
 Gear boxes
 Automobiles
 Machines requiring speed reduction or increase
Compound Gear Train:
A compound gear train is a type of gear arrangement where at least one shaft carries two or more gears that
are fixed to it and rotate with the same angular velocity, enabling a greater overall gear ratio to be achieved in
a smaller space than a simple gear train. Unlike simple gear trains where the final gear ratio depends only on
the first driver and last driven gears, a compound train uses multiple gear pairs, often with different numbers
of teeth, to achieve larger speed reductions or increases. The overall velocity ratio is found by multiplying the
velocity ratios of the individual gear pairs in the train.

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INTRODCTION TO MECHANICAL ENGINEERING 1BESC104D
Velocity Ratio

Applications
 Gear boxes in automobiles
 Machine tools (like lathes, milling machines)
 Watches and clocks
 Industrial machinery needing high torque transmission

Automatic and CVT Transmission:

An automatic transmission uses hydraulic pressure and planetary gearsets to automatically select and
engage fixed gear ratios, providing a traditional driving experience.
A Continuously Variable Transmission (CVT) is a type of automatic transmission that uses a belt
and pulley system to provide an infinite range of seamlessly shifting gear ratios for optimal engine
efficiency and smoother acceleration.
Automatic Transmission (Traditional Automatic)
 Mechanism: Uses hydraulic systems and planetary gearsets to achieve different gear ratios.
 Shifting: Operates with a fixed number of gears (e.g., 6 or 8) that are engaged and disengaged
sequentially.
 Experience: Offers a more engaging driving experience with noticeable gear shifts, providing a
connected feel to the drive.
 Best Use: Excels in stop-and-go traffic and offers a wide gear ratio spread for smooth power delivery,
though it may offer lower fuel economy compared to manuals or CVTs.

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INTRODCTION TO MECHANICAL ENGINEERING 1BESC104D
CVT (Continuously Variable Transmission)
 Mechanism: Utilizes a system of two variable-diameter pulleys connected by a belt or chain, allowing
for an infinite number of gear ratios.
 Shifting: Provides seamless, step-less shifts as the pulley diameters continuously adjust, offering an
unlimited range of gear ratios.
 Experience: Delivers smooth, uninterrupted acceleration and a more consistent engine RPM, which
can lead to better fuel economy.
 Best Use: Maximizes efficiency by keeping the engine in its most efficient RPM band, resulting in
smoother operation and improved mileage over traditional automatics.
 Other Names: Often referred to as a step-less, single-speed, or shiftless transmission.

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