MODULE2

CLUTCH

Thecl ut
chi shousedbet weent heengi neandt ransmi ssionwher eitpr ovidesa
mechani calcoupl ingbet weent heengi ne' sflywheelandt het ransmi ssioni nputshaf t
.
Thecl utchi soper atedbyal i
nkaget hatext endsfrom t hepassengercompar tmentt o
thecl ut
chhousi ng.Thepur poseoft hecl utchist odi sconnectt heengi nef rom t he
driv
enwheel swhenav ehicl
eischangi nggear sorbeingst art
edf r
om r est.Di sengagi ng
theclutchsepar atest hef l
ywheel,thecl utchplateandt hepr essurepl atef r
om each
other.Thef lywheeli sboltedtotheendoft hecr ankshaftandr otateswi thit.Thecl utch
plateissplinedtot hegear boxinor derforbot htorotatetoget herandt hepressur eplate
clampst heclutchpl atetot hef l
ywheel .Whent hepr essur eisr eleasedbydepr essing
theclutchpedal ,thecr ankshaftandgear boxi nputshaftr otatei ndependent ly.Whent he
footistakenof ftheyr otateasone.

REQUI
REMENTSOFACLUTCH

Thecl
utchmust

1.
Pickupi
tsl
oadsmoot
hlywi
thoutgr
aborcl
att
er.

2.
Hav
eadr
ivendi
scofl
owmomentofi
ner
ti
atoper
miteasyshi
ft
ing.

3.
Dampoutanyv
ibr
ati
onoft
hecr
ankshaf
ttopr
eventgearcl
att
er.

4.
Requi
rel
i
ttl
epedal
pressur
etooper
atei
t.

5.
Beeasyt
oadj
ustandser
vice.

KTUStudents.in
6.
Becheapt
omanuf
act
ure.

Positi
veClut ches:Int hi
st ypeofclutch,t heengagingcl ut
chsur f
acesinterl
ockto
produce ri
gi dj oi
ntt hey are sui
tabl
ef orsi t
uati
ons requiri
ng simpl
e and r api
d
di
sconnection,al t
hough theymustbe connect ed whil
e shafts ar
e st
ationeryand
unloaded,t
heengagi ngsur facesar
eusual l
yofjaw ty
pe.Thej awsmaybesquar ejaw
ty
peorspi raljaw type.Theyar edesi gnedempi ri
call
ybyconsi deri
ngcompr essiv
e
strengt
hoft hemat er
ialused.Themer i
tsoft heposi
ti
veclutchesare.
(i
) Si mple(ii
)Nosl i
p(ii
i)Noheatgener atedcompactandl owcost.

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Fri
cti
onClutches:Fr
icti
onClutcheswor kont hebasisoft hefr
icti
onalforcesdeveloped
betweenthet woormor esurfacesincontact .Fri
cti
onclutchesar eusually–ov erthe
j
awcl ut
chesduet othei
rbett
erperformance.Ther eisaslipinfri
cti
onclutch.Themer i
ts
are
(i
) Theyf ri
cti
onsurf
acescansl ipduringengagementwhi chenablest hedr
iverto
pickupandacceler
atetheloadwithmi ni
mum shock.
(i
i
) Theycanbeusedathi ghengagementspeedssi ncetheydonothav ejawor
teeth
(i
i
i) Smoot hengagementduet othegradual i
ncreaseinnormal f
orce.

Themaj
ort
y pesoff ri
cti
onclutchesare
(i
) Pl ateclutch(Singl
eplate)(
multi
plepl
ate)
(i
i
) Conecl utch
(i
i
i) Centri
fugal cl
utch
(i
v) Dry
(v
) Magnet iccurrentcl
utches
(v
i) Eddycur rentclut
ches

Dri
venPl at
eInerti
a
Foref f
icientoper at
ionoft hecl utch,t hedri
ven-
platemusthav emi ni
mum possi ble
weightsot hatitpr oducesmi ni
mum ofspi n,i.
e.veryl i
ttl
eflywheelef fectwhent he
cl
utchisdi sengaged.Spi npr eventionisext r
emelyimportanttoalignthev ariouspairsof
dogteet hoft hegear s,f
orbot hconst antmeshandsy nchromeshgear ingar rangement.
Duri
ngt heengagementphase,t heal i
gnmentoft eethtakespl aceint heshor testti
me
wit
houtcausi ngexcessi vepr essure,wearandnoi sebet weent heini
tialchamf erofthe
dogt eeth.Smoot hnessofcl utchengagementi snormal lyobtainedbybui ldi
ngsome
sortofcushi oni
ngdev i
cei ntot hedr ivenplat
e.Forr apidslowingdownoft hedriven

KTUStudents.in
pl
ate,t hedi ameter,cent reofgr av i
tyandwei ghtoft hedr i
venplatei skeptt ot he
minimum f oragi vent or
quecar ry
ingcapaci t
y.

DrivenPl ateTor queTransmi ssionCapaci ty

Thet orquecapaci t
yofaf rictioncl utchincreaseswi tht heincreaseoft hecoef fi
cientof
fri
ctionoft her ubbingmat erials,thedi amet erand/ ort hespr i
ngt hr ustsandwi chi
ngt he
drivenpl ate.Thef ri
cti
onliningmat eri
alslimitthecoef fici
entoff ri
ctiontot heor derof
0.35.Mat erialswi t
hhighercoef fi
cientoff ri
ctionv aluesar eav ailable,buttheset endt o
beunst ableandt osnatchdur ingt ake-up.Increasingt hediamet eroft hedr i
ven- pl
ate
raisesitsi ner t
ia,andi t
st endencyt ocont i
nuespi nni ngwhent hedr i
ven-
platei sfreed
dur i
ngdi sengagedposi ti
onoft hecl utch.
Alsot herei sal imittotheclampi ngpr essuret owhi cht hef r
ict
ionl i
ningmat eri
almaybe
subjectedi fi ti
st omaintainitsf ri
ctionpr operti
esov eral ongper iodoft ime.

Mat eri
al Usedf orClutch
1Gr eycasti ron:Thecl utchdi scisgener all
ymadef r
om greycasti ron( FG300) .
Because
ofitshi ghheatandwearr esistantbuti tscer ami cbasedcomposi tesar eusedascl utch
discmat eri
alduetoi tshi ght hermal conduct ivit
yanddi ff
usi v
ity
.
2Si nter edbr ass:Sinteredbr assmat eri
ali susedascl utchpl atemat eri
albecauseof
thei
rr esi li
enceathi ghl oadsandhi ght emper aturesaswel last heircosti ncompar ison
toalter nat i
vefri
cti
onmat erial
s.
3Asbest os:Inpast ,Asbest oswasusedasacl utchplatemat er ialduet oitshighheat
resi
stanceandgoodst rengt h.Disadv ant ageofasbest osi st hati twillcreatel ung
cancersuchascol on,thr oatandesophageal cancer .
4E-Gl assf i
bercomposi te: Commer ciall
yE- Glassf i
bercomposi tei susedascl utchplate
mat erialsbecauseofi tsHi ghst i
ff
ness, hi ghst r
engt handr elati
vel ylowdensi t
y.
5Met alMat ri
xComposi t
es:Met alMat ri
xComposi t
esar ecomposedofamet alli
c
mat ri
x( Al,Mg,Fe,Cuet c)andadi spersedcer ami c(carbides,oxi de,)ormet all
icphase
(Pb,Mo, W etc).
6Al umi nium (Al)Mat ri
xSel ecti
on:Theuni quepr opert
iesofal umi ni
um composi t
esar e
bettercompeert oot herconv enti
onmat erials.

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SI
NGLEPLATECLUTCH

Asi nglepl ateiscommonl yusedi ncarsandl ightv ehicles.Ithasonl yonecl utch

pl
atewhi chi smount edont hespl inesoftheclutchshaf t
.Af lywheeli smount edont he
crankshaftoft heengi ne.Apr essur eplateisconnect edt ot hef l
ywheelt hr
ought he
boltsandcl utchspr i
ngs.I tisf r
eet osli
deont hecl utchshaf twiththemov ementof
cl
utchpedal .Whencl utchi si nengagedposi tion,thecl utchpl ateremai nsgr i
pped
betweenf lywheelandpr essurepl ate.Fr
icti
onliningsar epr ov i
dedonbot ht hesidesof
cl
utchpl ate.Ononesi decl utchpl ateisintouchwi thf l
ywheelandonot hersidewi th

KTUStudents.in
pressurepl ate.Duet of r
icti
ononbot hsides,t hecl utchpl ater evolv
eswi thengi ne
fl
ywheel.Ther efore,clutcht ransmi tsenginepowert oclut chshaf t.Clutchshaf tis
connectedt ot ransmi ssion( orgearbox)ofaut omobi l
e.Thus,cl utchtransmi t
spower
fr
om engi netot ransmi ssionsy stem whichinturnr otateswheel sofengine.
Whent heclut
chpl atei
stobedi sengaged,thecl
utchpedali
spressed.Because
ofthi
spressurepl
atemov esbackandcl utchplat
eisdisengagedf
rom f
lywheel.Thus,
cl
utchshaftstopsrotat
ingev enifenginef l
ywheelisr
otati
ng.Int
hisposit
ion,power
doesnotreachthewheel sandv ehi
clealsostopsrunni
ng.Singl
epl
atecl
utchisshown
i
nFigure

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MULTIPLATECLUTCH

Multi-
plat
eclutchconsi st
sofmor et hanonecl utchpl atescontr
arytosi ngl eplate
clutchwhi chconsi stsofonl yonepl ate.Fr icti
onsur facesar emadei ncaseofmul ti
-
platecl ut
ch.Duet oi ncreasednumberoff r
ictionsur f
aces,amul t
i-
plat
ecl utchcan
transmi tlargetorque.Ther efor
e,itisusedi nr aci
ngcar sandheav ymot orv ehicles
whi chhav ehi ghengi nepower .Thecl utchpl at esareal ternati
vel
yf i
ttedwi thengi ne
shaf tandt heshaftofgearbox.Hepl atesar ef i
rml yhel
dbyt hef or
ceofcoi lspringsand
theyassembl edinadr um.Onepl ateslidesi nt hegroov esont hefl
ywheelandt henext
plateslidesonspi nespr ovi
dedonpr essur epl ate.Thus,eachal t
ernateplatesl i
desi n
groov esont heflywheelandt heot heronspl inesofpr essureplate.Ifwet aket wo
consecut i
v eplat
es,thenonehasi nnerandot herhasout erspl i
nes.

KTUStudents.in
Whent hecl utchpedalispressed,thepr essur
eplatemov esbackagainstthe
for
ceofcoilspri
ng, whentheclut
chplatesaredisengagedandenginefl
ywheelandgear
boxaredecoupl ed.Howev er
,whencl utchpedali snotpressedtheclutchremainin
engagedpositi
onandt hepowercanbet r
ansmi tt
edfrom enginefl
ywheeltothegear
box.Thi
stypeofcl utchhasbeenshowni nFigur
e

CENTRI
FUGALCLUTCH

Inthist ypeofcl utchest hespringsar eel i

minated altoget
herand onl yt he
centri
fugalforcei sused t o appl yther equi
red pressureforkeepi ng t
hecl utchi n
engagementposi t
ion.Theadv antageofthecent ri
fugalcl
utchist hatnoseparat
ecl utch
pedali srequir
ed.Thecl utchisoper at
edaut omat i
call
ydependi ngupont heengi ne
speed.Thismeanst hatcarcanbest oppedi ngearwi t
houtstall
ingtheengine.Similarl
y
whilestart
ing,thedr i
vercanf ir
stselectthegear ,putthecari ntothegearandsi mpl y
presstheacceleratorpedal.Thismakest hedr i
vingoperati
onv eryeasy.

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 Fi
gur
e shows a schemat i
c diagram ofa cent ri
fugalcl
utch.As the speed
i
ncreases,t
hewei ghtAf l
yoff,t
herebyoper at
ingthebel
lcranklev
erBt hatpr
essesthe
pl
ateC.Thi sforceist r
ansmitt
edt ot heplateDbymeansofspr ingsE.Thepl at
eD
contai
ningfr
ict
ionl i
ningisthuspr essedagai nstt
hefly
wheelFt herebyengagesthe
cl
utch.Spri
ngGser vestokeepthecl utchdisengagedatlowspeedsay500r pm.The
stopHl i
mit
stheamountofcent rif
ugal for
ce.

Semi centri
fugal
clut
ch
Thesecl utchesaresi mil
artot hecent r
if
ugalclut
chesonl ydif
ferenceisthatthese
clutchesusescent ri
fugalfor
ceaswel l
asspr ingf
orceforkeepi
ngitinengagedposit
ion.
Thespr i
ngsar edesi
gnedt otransmi
tthet orqueatnor
malspeeds, whil
ethecentr
if
ugal
forceassi stthet
orquet r
ansmitti
ngathigherspeed.
Itconsi
stsofthreeli
nesandwei ghtedleversandt hreeclutchspri
ngsalternat
ivel
y
arr
angedatequalspacesont hepr essur
epl at
e.Atnor malspeedswhent hepower
tr
ansmissi
onislowthespri
ngskeepst hecl
utchengagedont hepressurepl
ate.Athigh
speed,whenthepowert r
ansmi ssi
oni shigh,theweightsf l
yoffandt heleversalso
extendpr
essur
eont hepl
ate,t
huskeepi ngtheclut
chfi
r mlyengaged.

KTUStudents.in

PullTy peCl utch

Ani ncreasingnumberofnew v ehicl
esar ebei ngf ittedwi t
h“ pullty
pe”clut
ches.With
plentyofi nteresti nt hemar ketpl aceaboutt hedi ffer encesbet weenthenewpullty
pe
andt hetradi t
ional “pusht ype” .
Herei sasummar yoft hedi ffer
encesand  adv ant ages.
 
Thei ncreasingt or queout putofmoder nengi neshasr esulted
i
nar equirementf orcl utcheswi thhi ghercl ampl oad.But
because t he cl amp l oad i sdet ermi ned byt he di aphr agm
spring,thismeanst hatast i
fferdi aphr agm i sr equi redt o
i
ncr easethecl ampl oad.Butofcour set hest i
fferaspr ingi s,
thehar deri tist obend,whi chmeanst hatt hepedalef fortis
i
ncr eased,r esultinginwhati scalled“ heav ypedal ”.Andher e
i
swher eist hepr oblem occur s,becauset het endencyi n
moder ncar si sforgr eat ercomf ortandl essdr i
v eref for t
.
 
Att hispoi ntpl easenot et hatt hewor ds“ pul l
”and“ push”r efertot heact
iononthe
diaphragm, nott hemet hodofmov ingt her eleasel ev er.
 
Simpl ephy sicsandt hel awofl ev erst ell
sust hatt hegr eatertheleverl
engt
h,thel
ess

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theef fortrequiredt omov eamass.At raditionalpusht y
pecl utchut i
lisesonlyabout70-
75%oft heav ailablediaphr agm f ingerl engt ht oactonaf ulcrum poi ntandcauset he
releasebear ingt o“ push”t hedi aphr agm spr ing,t
herebyremov i
ngt hecl amploadf r
om
thecl utch. 
Seef i
gure1f orpusht ypecl utchoper ation.
 
Inapul ltypedesi gnt hefulcrum poi nti sr elocated,byhingingt hedi aphragm underthe
l
ipoft hecov erandt herebyl engt heni ngt hel everbyupt o30%.Ther el
easebear i
ng
“pulls”thediaphr agm t oremov et hecl ampl oadf r
om theclutch.
Figur e2showst heoper ati
onofapul ltypecl utch.
Thi smeanst hatf oragi venl ev erl engt h,t hepedalef f
ortwi llbe30% l essthanan
equi val
entpusht y
pedesi gn.Ther eforei napul lty
peclutch,fort hesamepedalef f
ortas
apusht ypeclutch, t
hecl ampl oadoft hecl ut chcanbei ncreasedby30%wi t
houtdriv
er
comf ort.
 
Mostol dermodelcar sl i
ket hepeugeot505useat r
adit
ionalpusht y peclutch,mostcar
model susedt hisclutchupunt iltheear ly90' sthenthecl utchwaschangedt oapul l
typecl utchfort heincreasingt orqueout putoft hemoder nengi nes.

KTUStudents.in
 
 
HowDoesACl utchWor k?
Whent heclut
chpedal ispr essed,acabl
eorhy dr
aulicpi
stonpushesont herel
easefork,
whichpressesthet hrow- outbearingagai
nstthemi ddl
eofthediaphragm spri
ng.Asthe
middleofthedi aphragm spr ingi
spushedi n,aser i
esofpinsneart heoutsideofthe
spri
ngcausest hespr ingt opullthepressureplateawayf r
om t heclutchdisc(see
bel
ow) .Thi
sreleasest hecl utchfr
om thespinni
ngengine.

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 GEARBOX

KTUStudents.in
NECESSITYOFGEARBOXI NANAUTOMOBI LE
•Thegearboxi snecessaryi
nthetransmissionsystem t
omai nt
ainenginespeedatt
he
mosteconomi calv
alueunderal
lcondit
ionsofv ehi
clemov ement
.
•Ani dealgearboxwoul dprovi
deani nfi
niterangeofgearr at
ios,sot hatt
heengi
ne
speedshouldbekeptatorneart hatthemaxi mum poweri sdevelopedwhat ev
ert
he
speedofthevehicl
e.

FUNCTI ONOFGEARBOX
Anaut omobileisabletoprov i
devaryi
ngspeedandt orquethroughitsgearbox.Vari
ous
functi
onsofagearboxar elistedbel
ow:
(a)Toprovidehightorqueatt heti
meofst arti
ng,vehicleaccel
erati
on,cl
imbingupahill
.
(b)Topr ovi
demor et hanf orwardspeedsbypr ovidingmor ethanonegearr at
ios.I
n
moder ncars,fiv
ef or
war dgear sandr ev
ersegeari spr ovi
ded.Forgivenenginespeed,
higherspeedcanbeobt ai
nedbyr unninginhigher(4thand5t h)gears.
(c)Gearboxpr ovi
desar eversegearfordriv
ingthev ehiclei
nreversedir
ecti
on.

TYPESOFGEARBOXES
(a)
Selectiv
ety pegearboxes:
(i
)Sli
dingmeshgearbox
(i
i
)Const antmeshgearbox
(i
i
i)Synchromeshgearbox
(b)Progressi
v etypegearbox
(c)Epicycl
ictypegearbox.

SLI
DINGMESHGEARBOX

Iti
ssi mplesttypeofgearboxoutoft heav ailablegearboxes.Int
hist ypeofgear
box,gearsar echangedbysl idi
ngonegearont heot her.Thisgearboxconsistsoft hr
ee
shafts;mai nshaf t
,clutchshaftandacount ershaf t
.Inaf ourspeedgearbox( which
i
ncludesoner eversegear),thecountershafthasf ourgear swhichareri
gidlyconnected
toit.Clutchshaf thasonegearandmai nshaf thast wogear s.Thetw ogear sonthe
mainshaf tcansl ideint hehor i
zontaldir
ect i
onal ongthespl inesofthemai nshaft.
Howev er,thegear sont hecount ershaftcannotsl ide.Thecl ut
chgearisrigidlyfi
xedto
theclutchshaf t
.Itisalway sconnectedtothecount ershaftdriv
egear.Thet wogear son

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themainshaf tcanbeslidedbyt heshif
tery
okebyoperati
ngt heshi f
tlever(notshown
i
nFi gur
es).Thesetwogear sar esecondgearandlow/reversegearr especti
vely
.These
gearscanbemeshedwi thcor respondi
nggearsonthecount ershaf
twi t
ht hehelpof
shif
teryokeandshiftl
ever.Shiftleveri
soperat
edbyhandi nfourwheel er
sf orchangi
ng
thegears.Areversei
dlergearismount edonanother(
thir
d)shaf tandisalway si
nmesh
withrev
ersegearoncount ershaft.

KTUStudents.in

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Neut
ral
Posi
ti
on

Figureshowssl i
dingmeshgearboxi nneutr
alposi
ti
on.Int hi
spositi
on,t he
enginei si nr unni
ngcondi t
ion,clut
chremainsengagedandcl utchgeardrivest he
countershaf tdri
vegear .Thedi r
ecti
onofrot
ati
onofcounter
shaftisopposit
etot hatof
clut
chshaf t.InthispositionIst,I
IndandII
Ir
dandr ever
segearsar efr
ee.Thus,mai n
(tr
ansmi ssion)shaf tdoesnotr otateandaut
omobilewheel
sdonotr ot
ate.Sov ehi
cle
remainsst ationary
.

KTUStudents.in
Fi
rstGear

Whenf i
rstgearpositi
onisselectedbyt heshi
ftlever,f
irstgear(largegear)on
themai nshaftsli
desandi sconnect
edt ofi
rstgearonthecount ershaft
.Thedirecti
onof
rotat
ionofmai nshaftissameast hatofcl utchshaf
t .Infirstgear,smal lgearof
countershaf
tmesheswi thlar
gergearonmai nshaft
,speedr educt i
onint herat
io3:1
(approxi
mate)isobtained.

SecondGear

Whensecondgeari sselectedbytheshif
tlever
,secondgearoncount er
shaf
t
mesheswithsecondgear(smallgearonmainshaft)onthemainshaft
.Thedir
ecti
onof
mainshaftissameast hatofcl utchshaf
t.Speedreduct
ionoft heorderof2:1is
obt
ainedi
nsecondgear.

Thi
rdGear

Inthir
dgear ,
themainshaf tissl
idedaxial
lytowardstheclut
chshaftsot
hatmai n
shaftisdirect
lyconnect
edt othecl ut
chshaft.Inthisposi
ti
on,themainshaftr
otat
esat
thespeedofcl ut
chshaft.Thus,aspeedr atioof1:1i sobtai
ned.Itcanbenotedthat
theclutchgeari sdir
ect
lyconnect edtoenginecrankshaftandmai nshafti
sconnected
tothewheel sthroughpr
opellershaft.

Rev
erseGear

Whent heshiftl
everisoperatedtoengaget hereversegear ,thelar
ger(r
everse)
gearoft hemai nshaftmesheswi ththereversei
dlergear .Reversei dl
ergeari
salway s
connectedt oreversegearoncountershaf
t.Thereverseidlergearbet weencount
ershaft
rev
ersegearandmai nshaftl
argergearchangesthedi r
ectionofr otati
onofmainshaf t
.
Thus,thedi rect
ionofmai nshaftbecomesopposi tetot hatofcl ut
chshaf t
.Theref
ore,
wheelsoft heaut omobil
estar
tmov inginbackwarddirecti
on.

CONSTANTMESHGEARBOX

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 Asi
mpli
fi
eddiagr
am ofconstantmeshboxhasbeenshowni nFig.Inthi
sgear
box,allgears on the maint ransmissi
on shaft ar
e constant
ly connect
ed to
corr
espondi
nggear
soncount ershaftorlayshaft
.Inaddit
ion,t
wodogcl ut
chesare
provi
dedonthemai
nshaft.Onedog

KTUStudents.in

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cl
utchi
sbetweenthesecondgearandcut
chgearandanotheri
sbetweenthef
ir
stgear
andrev
ersegear
.Spl
inesareoutonmai
nshaf
tsothatal
lthegearsar
efeedonit

KTUStudents.in
Dogcl
count
fol
l
ut
er
ows:

ForThr
chescanal
shaf

eeFor
tar

war
egi
sosl
ddil
yf

dandOneRev
i
deonmai
i

er
xedt
oit
nshaf
.Di

seGear
ffer
tandrot
at
entgearr
ewi
at
i
t
hi
os(
t
.Howev
speedr
ati
er
,al
lt
os)ar
hegear
eobtai
son
nedas

Topor3r dspeedgari sobtai

nedwhent heleftdogcl ut
chisslidedt ol
efttomesh
wit
hcl utchgearbyusi ngt hegearshiftlever
.Int hi
scase,mai nshaf trot
atesatt he
samespeedast hatofclutchgearorenginecrankshaftspeedwhi chismaxi mum speed.
Speedr ati
oobt ainedis1:1.Secondgearisobtainedwhendogcut ch(leftsi
de)meshes
wit
hsecondgear .Inthisconditi
onclutchgearr ot
atest hedrivegearoncount er
shaft
andcount er shaftdr i
vesthesecondgearont hemai nshaf t
.Allot hergearsonmai n
shaftaref ree,sot heydonotmov e.I
nt hesamemanner ,fi
rstgeari sobtainedwhen
ri
ghthandsi dedogcl ut
chmesheswi thfir
stgear.Rev ersegearisobt ai
nedwhenr ight
si
dedogcl utchmesheswi threv
ersegearonmai nshaf t.

Adv
ant
ageofConst
antMeshGearBox

Si
nceallthegearsareinconstantmesh,wearandt earofgearsandany
possi
bledamageofgearsdonotoccuri nengagi
nganddi
sengagi
nggears.Al
so,any
soundarenotgener
atedi
nengaged/
disengaged

SYNCHROMESHGEARBOX

Thi
st y
peofgearboxissimil
artotheconst antmeshtypegear
box.Insteadof
usingdogclut
chesheresy
nchroni
zer
sar eused.Themoderncarsusehel
icalgearsand
synchr
omeshdev icesingear
boxes,thatsynchronizet
herotati
onofgearst hatare
abouttobemeshed.

sy
nchr
oni
zer
s

Thi
sty
peofgear
boxi
ssi
mil
art
otheconst
antmesht
ypei
nthatal
lthegear
son

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themainshaf tar ei
nconst antmeshwi ththecor respondinggearsont helayshaft.The
gearsont hel ayshaftarefixedtoitwhi l
et hoseont hemainshaf tar
ef r
eetor otateon
thesame.I tswor ki
ngisalsosi mi
lartot heconst antmesht ype,butintheformert here
i
sonedef i
niteimprovementov erthel att
er.Thisist heprovi
sionofsynchromeshdev ice
whichav oidst henecessit
yofdoubl e-declut
ching.Thepar t
sthatulti
mat el
yar etobe
engagedar ef i
rstbroughti nt
of r
icti
onalcont act ,whichequalizestheirspeed,af ter
whichthesemaybeengagedsmoot hl
y .

KTUStudents.in

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Figureshowst heconst ruct
ionandwor ki
ngofasynchr
omeshgearbox.I
nmostoft he
cars,however,thesy nchromeshdevicesarenotfi
tt
edtoallt
hegearsasisshowni n
thisfigur
e.Theyar ef i
ttedonlyont hehighgear
sandont helow andrev
ersegears
ordinarydogclutchesareonlyprov
ided.Thisi
sdonetor
educethecost
.

Asy nchr
o'spurposei
stoallowthecol l
arandt hegeart
omakef ri
cti
onalcont act
befor
et hedogt eet
hmakecont act.Thislet
st hecollarandthegearsynchronizest hei
r

KTUStudents.in
speedsbef oret
heteethneedtoengage, l
i
ket his:Theconeont hebl
uegearf i
tsintot he
cone-shapedareainthecoll
ar,
andf r
ict
ionbet weent heconeandthecoll
arsy nchronize
thecollarandthegear.Theouterporti
onoft hecol l
arthensli
dessothatthedogt eeth
canengaget hegear.

OVERDRI
VE

Thepr i
ncipleoftheov erdri
veisill
ustr
atedinfigure,whi chshowsasi mpleepicycli
cgear
trai
n.Inthisthegearboxout putshaftisconnect edt ot hepl anetcar r
ierri
ngwhi lethe
annulusorr i
nggeari sat t
achedt otheouterraceoft hef ree-wheeluni tandfrom thisto
theoutputshaft;thelatterdri
vesthepropellershaftt hrought hefrontuni ver
salcoupling.
Thesunwheeli sther eacti
onmemberoft hegeart rainandwheni tislockedtot hegear
boxout put-orov er
driveinput-shaftt
hepl anetcar ri
erwhi chisdr ivenbyt hegearbow
shaftrotatesaboutthesunwheelcar r
yingwi t
hitt hepi nionwheel swhi chinturn,dri
ve

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theannulusgearandwi thittheoutputshafttot
hepropell
ershaft
.Theannul
usr ot
ates
moreslowl ythantheplanetcarri
erthusgivingalowergearrati
othanfordi
rectdrive.
Thepositioninwhicht
hesunwheeli slockedtothegearboxshaft,
whichhasjustbeen
descr
ibed, gi
vestheov
er dr
iverequi
rements.

KTUStudents.in

For more study materials: WWW.KTUSTUDENTS.IN

OVERDRI
VEOPERATI
ONS

Di
rectdr
ivecondi
ti
ons

Toobt ai
ndi rectdri
vetheoverdr
ivegearmustbel ockedinsomemannersoast o
rotateasonesol iduni t
.Thisisdonebyconnect ingthesungearsol i
dlywit
ht hepl anet

KTUStudents.in
carrier
.Thedr i
vefrom thegearboxshaf ti
sthent akenthroughthelockedepi
cy cli
cgear
trainandthencet hroughthefreewheeltotheov erdr
iveoutputshaft
.Theref
ore, wheni n
directdri
vethepr opell
ershaftsidecanr otat
ef asterthanthegearboxshaf t.Since,
howev er,t
hedi rectdr i
vei sonlyusedatspeedsbel ow about28t o30m. p.h,this
adv ant
ageisonl yreali
zedattheseattheselowerspeeds.

Compl
eteov
erdr
ive

Havi
ngexplai
nedthepr i
nci
pleofthisoverdr
ive,thepurposesoft hevar
ious
componentsshoul
dbebetterunderst
oodbyrefer
encet otheil
l
ustrat
ionofacomplete
over
dri
ve,asusedoncarsfit
tedwiththr
ee-
speedgearboxes.Theannul usorri
nggear
andtheouterr
aceofthef
ree-wheel
arespli
nedtotheoverdri
vemainshaft.

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TYPESOFDRI
VES

KTUStudents.in
Two-
wheel
dri
ve

Forfour
-wheel
ed vehi
cles,two-wheeldri
ve descr
ibes v
ehicl
es thatt
ransmit
t
orquetoatmosttwor oadwheels,ref
err
edt oasei
therfr
ont-orrear
-wheeldr
ive.The
t
erm 4x2i
salsoused,
toindi
catefourtot
alroad-
wheelswit
htwobeingdriv
en.

Forv
ehi
cl
esthathavepar
ti
alf
our
-wheeldr
ive,
theter
mtwo-wheeldr
iver
efer
st o
t
hemodewhenfour
-wheel
dri
vei
sdeact
ivat
edandtorquei
sappl
i
edtoonlytwowheels.

Four
-wheel
dri
veoral
l
-wheel
dri
ve

Thi
sconf i
gur
ati
onall
owsallfourroadwheel
stor
eceiv
etorquefrom t
hepower
pl
antsi
multaneousl
y.I
tisof
tenusedinral
lyr
aci
ngonmostl
ypavedroads.

Four-wheeldr i
vei scommoni noff-
roadvehi
clesbecausepower ingal lf
ourwheels
providesbettercontrolonlooseandsl i
pper
ysurfaces.Four
-wheeldri
vemanufactur
ers
hav ediff
erentsy stemssuchas" HighRange4WD"and " Low Range4WD" .These
systemsmaypr ovi
deaddedf eat
uressuchasv ar
yingoftorquedistr
ibuti
onbetween
axlesorvaryi
nggearr at
ios.

Commont er
msf ort
hisconfi
gurat
ioni
ncl
udef
our
-wheeldr
ive,4WD,4x4(
pronounced
"
four
-by
-four
"),
andal
l-
wheeldri
ve(AWD).

Fr
ont
-wheel
dri
ve

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 Fr
ont-
wheeldriv
e(FWD)vehi
cles'enginesdr
ivethefr
ontwheel
s.Usi
ngthefr
ont
wheelsfordeliv
eryofpoweraswellasst eeri
ngall
owst hedr
ivi
ngfor
cetoactinthe
samedi rect
ionast hewheeli
spointing.Thi sl
ayoutiscommonlyusedi nmodern
passengercars.

Rear
-wheel
dri
ve

Rear-wheel dr
ive(
RWD)t ypi
call
yplacestheengi
neinthefrontofthev ehi
cle,
with
adr
iveshaftrunningthelengt
hoft hevehicl
etothediff
erent
ialt
ransmission.Howev er
,
mi
dengi neandr earengi
nelayoutscanalsoused.

KTUStudents.in

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 Itwasacommonl ayoutusedinautomobi
lest
hroughoutt
he20thcent
ury.Att
hist
ime,FWD
desi
gnswerenotpracti
calduet ocomplexi
ty(i
nFWD,engi nepowerandsteeri
ngmustbothbe
combinedi
nthef
rontaxl
e).

FLUI
DCOUPLI
NG/TORQUECONVERTER

WORKI
NGPRI
NCI
PLE

KTUStudents.in
Fir
stofallwewillhavetounderst
andthatfir
stt
woelementsthatwehavedi
scussedabove
maywor kaspumporast ur
binealso.Impell
erswil
lactashy dr
auli
cturbi
neandalso actas
cent
ri
fugalpump.I
nputenergysour
cewi l
lbeei
therel
ect
ri
cmotorordi
eselengi
ne.

Enginewi l
l beconnectedwiththedri
vingimpell
eri.e.Pump.Mechani calenergy(Ki
neti
cener gy
)
wil
lbet ransmittedt otheoilwit
ht hehelpofthepumpi ncoupling.Duetot hecent r
if
ugalacti
on,Oil
wil
lmov ear oundt hetur
binebladesi nthedirect
ionofout si
deofcoupl i
ng.Tur bi
newi l
labsorbt he
ki
neticenergyandwi llpr
oduceat orquewhichwi l
lbealway sequaltotheinputtorque.Hence,output
shaftwil
lber otated.Nowt hequest i
onsaregenerall
ybeingasked, howimpel l
erturnsthetur
bine.We
canunder standt heconceptofr otat
ionofturbinewiththehelpoff oll
owingf i
gurewher eonef anis
acti
ngaspumpf ort r
ansmitt
ingtheairtowardsthenextfanbladet orot
atethebladeofsecondf an.

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