AEN Chirag

GOVERNMENT POLYTECHNIC PEN
DEPARTMENT OF MECHANICAL ENGINEERING
PROJECT REPORT OF
Gearbox and its mechanism
GUIDED BY
Mr. A. R. YADGIRE
GOVERNMENT POLYTECHNIC PEN
This is to certify that the following student of fifth semester of Diploma

in Mechanical Engineering of institute Government Polytechnic Pen (0129) has
completed the micro-project satisfactorily in course AUTOMOBILE ENGINEERING for
the Academic Year 2023-24 as prescribed in curriculum.
Name of the students Roll no.
Chirag Rakesh Patil 3536
Mr. A. R. YADGIRE Mr. V. S. SONAWANE DR. N. G. KULKARNI
(Project Guide) (Head of the Department) (Head of the Institute)

ACKNOWLEDGEMENT
It is with profoundly sense of gratitude that we acknowledge from our guide Mr. A. R.
Yadgire, he has been guide in the true of word a guide who satisfaction from our word
and progress.
We are highly obliged to Mr. V. S. Sonawane Head of Mechanical Department for

aberrance and good co-operation given to us further bringing this to almost standard.
We are grateful to our principal Dr. N. G. Kulkarni for proceeding acknowledgement to

us in the connection of this project concluding . We appreciate the assistance of all staff
that helps us in for their sincere and obliging help to make our project successfully.
PART A
Micro-Project Proposal
GEARBOX AND ITS MECHANISM
1.0Brief Introduction :-
Gearbox is a mechanical device which uses a gear set—two or more
gears working together—to change the speed or direction of rotation in a machine.
Many transmissions have multiple gear ratios, but there are also transmissions that
use a single fixed-gear ratio. Most currently-produced passenger cars with gasoline
or diesel engines use transmissions with 5–8 forward gear ratios and one reverse
gear ratio. Electric vehicles typically use a single-speed or two-speed transmission.
2.0Aim of the Micro – Project :-

 Study the Drum Brake System in Automobile Engineering
3.0Course Outcomes Addressed:-

.
 Identify various elements of the given Drum Brake system.
 Explain with sketches the given Drum brake system Automobile
Engineering.
Part B
Drum Brake System
1.0 Brief Introduction :-
A drum brake is a type of mechanical braking system commonly used in vehicles

to slow down or stop their motion. This braking mechanism operates through the
interaction of friction between brake shoes and the inner surface of a drum-like
component attached to the wheel. Drum brakes have a long history and are still
found in various automotive applications, though they have become less common in
newer vehicles due to the emergence of more advanced disc brake systems. A drum
brake operates by utilising the friction generated when a set of shoes or pads exert
pressure outwards against a rotating, cylinder-shaped component known as a brake
drum. The term “drum brake” typically refers to a braking mechanism in which the
shoes apply pressure to the inner surface of the drum.
2.0Aim of the Micro – Project :-
Study the Drum Brake System in Automobile Engineering .
3.0Course Outcomes Addressed:-

 Identify various elements of Drum Brake system.
 Explain with sketches the given Drum Brake system of Automobile
Engineering.
4.0Actual Procedure Followed :-

Step 1: The project topic was assigned by the lecturer.
Step 2: Collect the information related the given topic.
Step 3: Make the project proposal.
Step 4: Make the report of microproject.
Step 5: Studied about the different componet
Step 6: Submit the microproject.
5.0Resources Required:-
Sr.no. Name of Specification Quantity Remarks

resources
1 Laptop HP Laptop 1
2 Browser Chrome 1
3 Pages A4 size 11
6.0literature View:-
Drum Brake Working Principle
: Drum braking system
Upon the driver's application of the brake pedal, the brake booster (also known as the servo
system) amplifies the force, which is then converted into hydraulic pressure (oil pressure) by
the master cylinder. This hydraulic pressure is transmitted through tubing filled with brake
fluid to the brake mechanisms located at each wheel. As the pressure reaches these brakes, it
engages pistons that are positioned on the brake assemblies of all four wheels.
Subsequently, these pistons exert pressure upon brake linings, composed of friction-inducing
materials, against the interior surfaces of the rotating brake drums that are synchronised with
the wheels' motion. The friction generated between the linings and the spinning drums causes
deceleration in the wheels' rotation, ultimately leading to the gradual reduction and eventual
halt of the vehicle's movement
Construction of a Drum Brake
 Construction of drum braking system
A drum brake consists of the following elements:
1)Backing Plate:
This component offers a sturdy foundation for other parts within the drum brake,
connected to the axle sleeve.
2)Brake Drum:
Affixed to the wheel hub, the brake drum rotates alongside the wheel. Often constructed
from cast iron, it displays resilience against heat and wear. The brake drum is visible
when observing an assembled drum brake and serves as the platform where braking
force is applied to decelerate or halt the vehicle.
3)Wheel Cylinder:
Housing two pistons—one at each end—the wheel cylinder is responsible for actuating
the brake shoes. By exerting pressure on the pistons, the cylinder propels the brake
shoes towards the drum, causing the vehicle to slow down or stop. Each wheel
necessitates one cylinder.
4)Brake Shoe:
These shoes press against the drum to create the friction essential for deceleration or
stopping. Attached to the backing but capable of sliding when the wheel cylinder applies
pressure, the brake shoe features an affixed lining composed of organic or metallic
compounds. This lining comes into direct contact with the drum and wears down with
usage. A set of two shoes constitutes each brake assembly—the primary shoe situated
closer to the vehicle’s front, and the secondary shoe positioned closer to the rear.
Depending on the type and brand, the brake shoes may be interchangeable.
5)Brake Shoe Adjuster:

This component ensures a consistent distance between the brake shoes and the drum,
even as the lining experiences wear over time.
6)Return Springs:
When the driver releases the brake pedal, these springs retract the brake shoes from
the drum.
Types of Drum Brake

Mechanical Drum Brake
The mechanical drum brake system encompasses applications in two-wheelers and
auto rickshaws. Within this setup, a cam is affixed to the brake linkage and pedal,
serving as the actuator for the brake shoes. Upon pressing the brake pedal, the cam
initiates a rotational motion, prompting the brake shoes to expand outward and make
contact with the drum.
Hydraulic Drum Brake
A step ahead of the mechanical system is the hydraulic drum brake, commonly found in cars. In
this design, the cam is replaced by a hydraulic wheel cylinder. Within this hydraulic setup, the
pistons of the wheel cylinder exert force to push the brake shoes outward. The brake shoes are
positioned on the anchor plate or braking plate, which consolidates the various components of
the brake system and secures them to the vehicle’s axle.
Pneumatic-Assisted Drum Brake:
The third variant, the pneumatic-assisted drum brake system, is actuated by air pressure and
follows the principles of the mechanical drum brake system. It relies on a larger cam or an ‘S-
shaped cam, commonly referred to as the “S-Cam” brake system. However, the distinctive
feature here is the utilization of high-pressure compressed air to activate a pneumatic piston,
setting the cam into motion.
Advantage of Drum Brakes
 Drum brakes have simplicity in design and components

 It has cost-effective manufacturing
 The maintenance demands for drum brakes are minimal
 These brakes have extended longevity
 Smooth braking engagement
 Drum brakes have a consistent performance
 These brakes have compartmentalised protection
 Drum brakes can be integrated into older vehicle models.
Disadvantages of Drum Brakes
 Drum brakes don’t stop as quickly as disc brakes.

 They can become less effective after being used for a while.
 The brake lining in some drum brakes contains harmful asbestos fibres.
 Drum brakes might not work well in wet conditions.
 Without asbestos linings, they can suddenly grab due to moisture.
5.0 Conclusion:
We have learned about the drum brake system study and its different types
6.0 Skills Developed/Learning Out Of this Microproject
 Time management
 Creativity
 Searching

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GOVERNMENT POLYTECHNIC PEN

DEPARTMENT OF MECHANICAL ENGINEERING

This is to certify that the following student of fifth semester of Diploma

Name of the students Roll no.

Chirag Rakesh Patil 3536

Mr. A. R. YADGIRE Mr. V. S. SONAWANE DR. N. G. KULKARNI

(Project Guide) (Head of the Department) (Head of the Institute)

We are highly obliged to Mr. V. S. Sonawane Head of Mechanical Department for

We are grateful to our principal Dr. N. G. Kulkarni for proceeding acknowledgement to

GEARBOX AND ITS MECHANISM

2.0Aim of the Micro – Project :-

3.0Course Outcomes Addressed:-

1.0 Brief Introduction :-

A drum brake is a type of mechanical braking system commonly used in vehicles

2.0Aim of the Micro – Project :-

Study the Drum Brake System in Automobile Engineering .

3.0Course Outcomes Addressed:-

4.0Actual Procedure Followed :-

Sr.no. Name of Specification Quantity Remarks

Drum Brake Working Principle

: Drum braking system

 Construction of drum braking system

A drum brake consists of the following elements:

5)Brake Shoe Adjuster:

Types of Drum Brake

Hydraulic Drum Brake

Pneumatic-Assisted Drum Brake:

Advantage of Drum Brakes

 Drum brakes have simplicity in design and components

Disadvantages of Drum Brakes

 Drum brakes don’t stop as quickly as disc brakes.

6.0 Skills Developed/Learning Out Of this Microproject

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