Gear Box

A gearbox is a mechanical method of transferring energy from one device to another and is
used to increase torque while reducing speed. Torque is the power generated through the
bending or twisting of a solid material. This term is often used interchangeably with
transmission. Located at the junction point of a power shaft, the gearbox is often used to create
a right angle change in direction, as is seen in a rotary mower or a helicopter. Each unit is made
with a specific purpose in mind, and the gear ratio used is designed to provide the level of force
required. This ratio is fixed and cannot be changed once the box is constructed. The only
possible modification after the fact is an adjustment that allows the shaft speed to increase,
along with a corresponding reduction in torque. In a situation where multiple speeds are
needed, a transmission with multiple gears can be used to increase torque while slowing down
the output speed. This design is commonly found in automobile transmissions. The same
principle can be used to create an overdrive gear that increases output speed while decreasing
torque.

Principle Of Gearing
Consider a simple 4-gear train. It consists of a driving gear A on input shaft and a driven gear
D on the output shaft. In between the two gears there are two intermediate gears B, C. Each of
these gears are mounted on separate shaft.
We notice that:
Gear A drives Gear B
𝑁𝑏 𝑇
= 𝑎
𝑁𝑎 𝑇𝑏
Gear B drives Gear C
𝑁𝑐 𝑇
= 𝑏
𝑁𝑏 𝑇𝑐
Gear C drives Gear D
𝑁𝑑 𝑇
= 𝑐
𝑁𝑐 𝑇𝑑
Therefore, the overall speed ratios are:
𝑁𝑑 𝑇 𝑇 𝑇 𝑇
= 𝑐 x 𝑏 x 𝑎 = 𝑎
𝑁𝑎 𝑇𝑑 𝑇𝑐 𝑇𝑏 𝑇𝑑

Types of Gear Boxes:

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 Sliding Mesh Gear Box

It is the simplest gear box. The following figure shows 4-speed gear box in neutral position.
4 gears are connected to the lay shaft/counter shaft. A reverse idler gear is mounted on another
shaft and always remains connected to the reverse gear of countershaft. This “H” shift pattern
enables the driver to select four different gear ratios and a reverse gear.
Gears in Neutral:
When the engine is running and clutch is engaged the clutch shaft gear drives the countershaft
gear. The countershaft rotates opposite in direction of the clutch shaft. In neutral position only
the clutch shaft gear is connected to the countershaft gear. Other gears are free and hence the
transmission main shaft is not turning. The vehicle is stationary.

First or low shaft gear:

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First or low shaft gear:
By operating the gear shift lever the larger gear on the main shaft is moved along the shaft to
mesh with the first gear of the counter shaft. The main shaft turns in the same direction as that
of the clutch shaft. Since the smaller countershaft is engaged with larger shaft gear a gear
reduction of approximately 4:1 is obtained i.e. the clutch shaft turns 4 times for each revolution
of main shaft.

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Second speed gear:
By operating the gear shift lever the third gear on the main shaft is moved along the shaft to
mesh with the third gear of the counter shaft. The main shaft turns in same direction as clutch
shaft. A gear reduction of approximately 3:1 is obtained.

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Third speed gear:
By operating the gear shift lever, the second gear of the main shaft and countershaft are
demeshed and then the third gear of the main shaft are forced axially against the clutch shaft
gear. External Teeth on the clutch shaft gear mesh with the internal teeth in the third and top
gear. The main shaft turns in same direction as clutch shaft. A gear reduction of approximately
2:1is obtained i.e. the clutch shaft turns 2 times for each revolution of main shaft.

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Fourth speed gear/ Top or High-Speed Gear:
By operating the gear shaft lever the third gears of the main and countershaft is demeshed and
the gears present on the main shaft along with the shaft is forced axially against the clutch shaft
gear. External teeth present on the main shaft engage with the internal teeth present on the main
shaft. The main shaft turns along with the clutch shaft and a gear ratio of approximately 1:1 is
obtained.

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Reverse gear:
By operating the gear shift lever, the last gear present on the main shaft is engaged with the
reverse idler gear. The reverse idler gear is always in mesh with the counters haft gear.
Interposing the idler gear between the counter-shaft reverse gear and main shaft gear, the main
shaft turns in the direction opposite to the clutch shaft. This reverses the rotation of the wheels
so that the wheel backs.

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 Constant Mesh Gear Box:

In this type of gear box, all gears of the main shaft are in constant mesh with the corresponding
gears of the countershaft (Lay shaft). Two dog clutches are provided on the main shaft- one
between the clutch gear and the second gear, and the other between the first gear and reverse
gear. The main shaft is splined and all the gears are free on it. Dog clutch can slide on the shaft
and rotates with it. All the gears on the countershaft are rigidly fixed with it.
When the left hand dog clutch is made to slide to the left by means of the gear shift
lever, it meshes with the clutch gear and the top speed gear is obtained. When the left hand dog
clutch meshes with the second gear, the second speed gear is obtained. Similarly by sliding the
right hand dog clutch to the left and right, the first speed gear and reverse gear are obtained
respectively. In this gear box because all the gears are in constant mesh they are safe from
being damaged and an unpleasant grinding sound does not occur while engaging and
disengaging them.

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 Synchromesh Gear Box:

In sliding Mesh Gear box the two meshing gears need to be revolve at equal peripheral speeds
to achieve a jerk less engagement and it is true for constant mesh gear box in which the
peripheral speeds of sliding dog and the corresponding gear on the output shaft must be equal.
𝑁1 𝑑2
The peripheral speed is given by : = , Where d1 and N1 are pitch circle diameter and
𝑁2 𝑑1
r.p.m. of gear and d2 and N2 diameter and r.p.m. of attached dog respectively. Now N1 ≠ N2
since d1 ≠ d2. Thus there is a difference in gear and dog which necessitates double declutching.
The driver has to disengage the clutch twice in quick succession therefore it is referred as
double declutching. There are two steps involved in this process:
The clutch is disengaged i.e. first declutching and the gear system is placed in its neutral
position. Now the clutch is reengaged and acceleration pedal is pressed to adjust the engine
speed according to driver’s judgment. The clutch is disengaged (i.e. second declutching) again
the appropriate gear is engaged and then the clutch is reengaged.
It is that gear box in which sliding synchronizing units are provided in place of sliding
dog clutches as in case of constant mesh gear box. With the help of synchronizing unit, the
speed of both the driving and driven shafts is synchronized before they are clutched together
through train of gears. The arrangement of power flow for the various gears remains the same
as in constant mesh gear box. The synchronizer is made of frictional materials. When the collar
tries to mesh with the gear, the synchronizer will touch the gear first and use friction force to
drive the gear to spin at the same speed as the collar. This will ensure that the collar is meshed
into the gear very smoothly without grinding. Synchromesh gear devices work on the principle
that two gears to be engaged are first bought into frictional contact which equalizes their speed
after which they are engaged readily and smoothly.
The following types of devices are mostly used in vehicles:

A synchronizing system is used for smooth meshing. Synchromesh works like a friction clutch.
In the following figure two conical surfaces cone-1 is the part of the collar and the cone-2 is
the part of the gear wheel. Cone1, 2 are revolving at different speeds. While cone-2 is revolving,
cone-1 gradually slides into it. Friction slows or speeds up the gear wheel. Finally both the
cones revolve at same speed.

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In this Fig collar and gear wheel are separate and they are revolving at different speeds. The
internal cone comes in contact with the outer cone of the gear wheel. Friction slows or speeds
up the gear wheel.
And when the collar and gear wheel rotate at same speed the spring loaded outer ring of
the collar is pushed forward. The dog slide smoothly into mesh without clashing. The collar
and gear wheel lock and revolve at same speed. This the principle of synchromesh.

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