Gears and Gearboxes

Gears are used to transmit power at uniform angular velocity from one shaft to another. When
two shafts are closed to each other in a contact form, gear drive is recommended. It is used for
different purposed such as:
1. To change the speed of rotation
2. To change the direction of rotation
3. To change the direction of shafting

Common gears used for different conditions are:

1. Spur gear
2. Worm gear
3. Bevel gear
4. Helical gear
5. Spiral gear

1. Spur gear: This gear is used to transmit power from one

shaft to another when they are parallel. It has the teeth cut
parallel to the axis of the shaft.

Fig.1: Spur gear

Agricultural Tractor Er. Babban Yadav SHUATS
2. Worm gear : Worm gear is used when two shafts are at right
angle but not intersecting each other. The worm is form of
thread, cut on a shaft. It meshes with worm wheel. It is used
when high velocity ratio is required in a limited space, such as
cream separator, hand chaff cutter etc.
Fig.2: Worm gear
3. Bevel Gear: It is used where the axis of the two
shafts are at right angle and can intersect each
other. When power has to turn a corner, bevel gears
are used. Plane bevel gears have straight teeth
while spiral bevel gears have twisted teeth.

4. Helical gear: It is used for transmitting power Fig.3: Bevel gear

between parallel shafts. The teeth is inclined to the
axis of the wheel which helps in meshing more than
two teeth at a time and remain in contact longer
than straight teeth.

5. Spiral Gear: When two shafts are placed at an

angle, spiral gear is used. Fig.4: Helical gear

Agricultural Tractor Er. Babban Yadav SHUATS

 Gearboxes of tractor:

Source: M&M online training

Agricultural Tractor Er. Babban Yadav SHUATS

 In automobiles the reduction from engine to wheel is almost 50 – 60 times.
To achieve this 50-60 times reduction in automobile, there are only two reductions
in transmission.
1. First reduction in gearbox
2. Second reduction in wheel and pinion

Source: M&M online training

Agricultural Tractor Er. Babban Yadav SHUATS

Source: M&M online training

Agricultural Tractor Er. Babban Yadav SHUATS

 Whereas in tractor the reduction from engine to wheel is almost 200 times.

To achieve this 200 times reduction, in tractor generally there are three reductions in
transmission.

1. First in gearbox
2. Second in crown wheel and pinion (Differential)
3. Third in bull pinion (final drive)

Source: M&M online training

Agricultural Tractor Er. Babban Yadav SHUATS

Source: M&M online training

Agricultural Tractor Er. Babban Yadav SHUATS

Source: M&M online training

Agricultural Tractor Er. Babban Yadav SHUATS

Agricultural Tractor Er. Babban Yadav SHUATS
Gearboxes of tractor:
❑ Since the torque requirement for doing the various agricultural operations is continuously
varying, there is a constant need for changing the set of gears involved in transmission of
the engine power to the wheels.
❑ There are a number of ways in which gears can be combined to alter the torque being
supplied to the tractor wheels. A series of gears are often combined together in a Gear
Box in an orderly manner.
❑ The automobile transmission gear boxes can be classified into different categories based
on the method in which the gears are meshed and speed ratios selected.
Gear boxes used for transmission systems are classified into:

1. Sliding Mesh Gear Box

2. Constant Mesh Gear Box
3. Synchromesh Gear Box

The main components of the gear box are:

1. Gear Box housing
2. Gear shafts
3. Gears
4. Bearings

Agricultural Tractor Er. Babban Yadav SHUATS

 ❑ The gear box housing is the outer casing, usually made of cast iron, that houses the various
shafts and gears inside. It also contains the gear box oil (SAE 90) for lubrication of the
gears.
There are three types of shafts inside the gear box:
• Input shaft (also called primary shaft or clutch shaft)
• Counter shaft (also called lay shaft or auxiliary shaft)
• Main shaft (also called secondary shaft or out shaft)
❑ The gears on these respective shafts are called by the name of the shaft i.e. input pinion,
counter shaft gear, main shaft gear.

❑ On the primary shaft is only one gear (helical

type). The primary shaft takes the rotational power
from the clutch. The clutch plate is mounted on
one end of this shaft, the one side which is splined.

❑ The helical gear on the primary shaft is inside the

gear box housing and is meshed to another helical
gear on the counter shaft. All the gears on the
counter shaft are fixed to the counter shaft and
rotate along with the shaft.
Fig. 5: Gear box

Agricultural Tractor Er. Babban Yadav SHUATS

 ❑ While construction and working of primary and counter shafts in case of all the three
types of gear boxes is similar, the construction and working of the main shaft gears.
❑ The main shaft is splined, but the main shaft gears sit on the main shaft in different ways
depending on which gear box these are on. The construction and working of the gear
boxes is described hereunder:
1. Sliding Mesh Gear Box:
❑ This is the oldest and the simplest of automotive gear boxes. As the name suggests,
the selected main shaft gear is slid over the main shaft to mesh with corresponding
gear on the counter shaft. While the main shaft is splined, the main shaft gears are
splined from inside, such that there is a positive motion between the main shaft and
the main shaft gears.

Cross-sectional view of a Sliding Mesh Gear Box:

1. Input drive gear
2. Counter shaft
3. Main shaft
4. 1st gear
5. 2nd gear
6. 3rd gear
Fig. 6: Sliding mesh gear box

Agricultural Tractor Er. Babban Yadav SHUATS

❑ At any given time, only one set (pair) of main shaft and countershaft gear are in mesh with
each other. In case two pairs get meshed, they will tend to rotate the main shaft at different
speeds, leading to breakage of either the main shaft or the meshed gears.

❑ When a particular gear is to be meshed, it is slid over the main shaft by its collar and is
made to mesh with the corresponding counter shaft gear.

❑ During the neutral position, none of the main shaft gears are engaged to the counter shaft
gears. Depending on the speed-torque requirement, the gears of main shaft is slid to mesh
with the respective gear on the counter shaft.
2. Constant Mesh Gear Box
❑ In case of constant mesh type of gear box all the gears of main shaft are constantly meshed
to the corresponding gears on the counter shaft as shown in the figure 7.
❑ Similar to the sliding mesh gear box, the main shaft is splined in this case too. But since all
the gears on the main shaft are meshed, these are free to rotate on the splined main shaft.
To transmit power an arrangement of fixed dog clutch and sliding dog clutch is used.

❑ The main shaft gears are free to rotate on the main shaft. The fixed dog clutch, placed
between two gears is splined from inside in such a way that its rotation is associated with
the main shaft i.e. when the fixed dog clutch rotates, the main shaft rotates and vice versa.

Agricultural Tractor Er. Babban Yadav SHUATS

❑ Now when the gear A is to be meshed, the sliding dog
clutch is moved to the left so that it locks the movement
of the gear to that of the fixed dog clutch.
❑ Now the gear is meshed to the corresponding gear of the 3 1
counter shaft. When this gear gets locked to the fixed dog
clutch, the power from the gear is transmitted to the main
shaft through the fixed dog clutch. 2
❑ All this while the other gears continue to rotate freely on 4
the main shaft without any interference Fig. 7: Constant mesh gear box
❑ To engage the gear, the clutch is disengaged, but the gears are still rotating because of their
momentum, the selected sliding dog clutch is moved as per requirement towards the gear that
is to be engaged.
❑ As the relative motion between the gear and the dog clutches reduces, the sliding dog clutch
engages with the selected gear and the clutch can be gradually engaged.

❑ In case of the constant mesh gear box, the clutch has to be pressed twice while moving from
one gear to another. This is done in such a way that the clutch is pressed once for moving
from the gear to neutral position and the second time for moving from neutral to other gear.
This process of pressing the clutch twice is called double de-clutching.

Agricultural Tractor Er. Babban Yadav SHUATS

3. Synchromesh Gear Box:
❑ Synchromesh is an advancement over the constant mesh gear box. A synchronizing unit is
provided to assisting in the gear changing.

Fig. 8: Synchromesh gear box

Agricultural Tractor Er. Babban Yadav SHUATS

❑ This type of gearbox is similar to the constant mesh type gearbox.

❑ Instead of using dog clutches here synchronizers are used.

❑ The modern cars use helical gears and synchromesh devices in gearboxes, that synchronize
the rotation of gears that are about to be meshed.

❑ Its working is also similar to the constant mesh type, but in the former there is one
definite improvement over the latter.

❑ This is the provision of synchromesh device which avoids the necessity of double-
declutching.

Agricultural Tractor Er. Babban Yadav SHUATS

 Rules of Gearing
FIRST GEAR:
❑ By operating gearshift lever, the larger gear on main shaft is made to slide and mesh with first
gear of countershaft.
❑ The main shaft turns in the same direction as clutch shaft in the ratio of 3:1.

SECOND GEAR:
❑ By operating gear shaft lever, the smaller gear on the main shaft is made to slide and mesh
with second gear of counter shaft.
❑ A gear reduction of approximately 2:1 is obtained.

TOP GEAR:
❑ By operating gearshift lever, the combined second speed gear and top speed gear is forced
axially against clutch shaft gear.
❑ External teeth on clutch gear mesh with internal teeth on top gear and the gear ratio is 1:1.

REVERSE GEAR:
❑ By operating gearshift lever, the larger gear of main shaft is meshed with reverse idler gear.

❑ The reverse idler gear is always on the mesh with counter shaft reverse gear. Interposing the
idler gear, between reverse and main shaft gear, the main shaft turns in a direction opposite to
clutch shaft

Agricultural Tractor Er. Babban Yadav SHUATS

NEUTRAL GEAR:
❑ When engine is running and the clutch is engaged, clutch shaft gear drives the drive
gear of the lay shaft and thus lay shaft also rotates.

❑ But the main shaft remains stationary as no gears in main shaft are engaged with lay
shaft gears.

Gear ratios: N 1 T1

Gear ratio between gear 1 and 6 can be obtained as:

𝑁1 𝑇2 𝑇4 𝑇6
= × ×
𝑁6 𝑇1 𝑇3 𝑇5
N 3 T3

N 2 T2
Note: Velocity ratio between first and last gear is equal
to the product of velocity ratios at each stage. N5T5

N 4 T4

N 6 T6

Agricultural Tractor Er. Babban Yadav SHUATS

 Working principle of gear change and gear shifting

In a gear box arrangement is provided on the top for gear changing mechanism. This includes
gear changing lever, gear changing spindles, gear forks etc.

Fig 17.1 shows a typical constant mesh gear box in an agricultural tractor. This gear box has
8+2 gear ratios i.e. 8 forward speed gear ratios and 2 reverse speed gear ratios.

Agricultural Tractor Er. Babban Yadav SHUATS

 Main gear lever
H/L lever

5 8 1 9

7 3
6 2

Range (High/Low)
Gear selector

Agricultural Tractor Er. Babban Yadav SHUATS

In this gear there are 5 shafts and a number of gears. There are also four sliding dog clutches –
3 on the upper shaft axis and 1 on the lower shaft.

Agricultural Tractor Er. Babban Yadav SHUATS

Agricultural Tractor Er. Babban Yadav SHUATS
DIFFERENTIAL

Agricultural Tractor Er. Babban Yadav SHUATS

When an automobile travels around a corner, the distance traveled by
the outside wheels is greater than that traveled by the inside wheels. If
the wheels are mounted on dead axles so that they turn independently
of each other, like the front wheels of an ordinary passenger vehicle,
they will turn at different speeds to compensate for the difference in
travel.

But, if the wheels are driven positively by the engine, a device is

necessary which will permit them to revolve at different speeds
without interfering with the propulsion system. To accomplish this
purpose a system of gears called the differential is provided.

The driving axle is one of the cross members which supports the load
of the tractor, and has the driving wheels at its ends. The driving axle
consists of a housing, a differential, two axle shafts (half axles), and
final drives (if required).

Agricultural Tractor Er. Babban Yadav SHUATS

Agricultural Tractor Er. Babban Yadav SHUATS
The differential is an important component of the driving axle. The main functions
performed by the differential system are:

1. Further reduces the rotations coming from the gear box before the same are
passed on to the rear axles.

2. Changes the direction of axis of rotation of the power by 90 degree i.e. from
being longitudinal to transverse direction.

3. To distribute power equally to both the rear driving axles when the tractor is
moving in straight ahead direction.

4. To distribute the power as per requirement to the driving axles during turning
i.e. more rotations are required by the outer wheel as compared to the inner
wheel-during turns.

Agricultural Tractor Er. Babban Yadav SHUATS

Agricultural Tractor Er. Babban Yadav SHUATS
 Half axle

Agricultural Tractor Er. Babban Yadav SHUATS

 Final Drive and PTO
FINAL DRIVES:

❑ Power transferred from differential to final work point through the final drive. On wheeled
machines, final drive provides final reduction in speed and increases torque to the drive
wheels.

❑ The size of driving gear is small and that of driven gear is much larger than driving gear.
The main purpose of final drive is to reduce the rear wheel speed and increase the torque for
development of more traction.

❑ It also helps in minimizing the number of gears and shafts in the gear box. It is provided in
the transmission system of tractor for following main reasons:

1. To provide a permanent gear reduction between engine and rear wheels.

2. To transmit the power from the gear box through 90 degree.

Most common types final drives in outdoor power equipment are straight axle drives, pinion
gear drives, and planetary gear drives. Figure 1 shows a final drive with straight.

Agricultural Tractor Er. Babban Yadav SHUATS

 Fig.1: Final drive of a tractor

❑ Planetary gear drives are more compact then pinion gear drives. Planetary gear drive very
strong and durable because spreads load over several gears. Power is transferred from
differential through a final drive shaft to the sun gear.

❑ As sun gear turns, it meshes with planet pinion gears. The planet pinion gears held in planet
pinion carrier that’s attached to the rear axle shaft. As sun gear and planet pinions turn, they
turn the carrier and rear axle shaft. This type final drive mechanism typically seen only in
larger garden tractors.

Agricultural Tractor Er. Babban Yadav SHUATS

Power Take off (PTO) drive:
❑Power take off (PTO) is any of several methods for taking power
from a power source, such as a running engine, and transmitting it to
an application such as an attached implement or separate machines.

❑Most commonly, it is a system comprising a splined output shaft on a

tractor or truck, designed so that a PTO shaft, a kind of drive shaft,
can be easily connected and disconnected, and a corresponding input
shaft on the application end. The power take-off allows implements to
draw energy from the engine.

❑It is provided at midway of rear of tractor to drive field machines

which require rotary power to operate their mechanism during field or
stationary works like threshing of crops, pumping water etc.
❑PTO shaft is located in relation to drawbar of tractor in such a way
that the drawbar and universal joints do not swing sideways.

Agricultural Tractor Er. Babban Yadav SHUATS

❑Recommended PTO speeds are 540 and 1000 rpm. In modern
tractors two standard PTO speeds i. e 540 ± 10 and 1000 ± 25 rpm
with 6 and 21 teeth in splined shafts respectively are available.

❑1000 rpm shaft is shorter than 540 rpm shaft which provides more
telescopic space and simplifies hitching of PTO operated
implements with tractor.

❑It also transmit nearly twice power than existing 540 rpm PTO for a
given torque.

Agricultural Tractor Er. Babban Yadav SHUATS

Agricultural Tractor Er. Babban Yadav SHUATS
Agricultural Tractor Er. Babban Yadav SHUATS
Source: M&M online training

Agricultural Tractor Er. Babban Yadav SHUATS

Source: M&M online training

Agricultural Tractor Er. Babban Yadav SHUATS

Source: M&M online training

Agricultural Tractor Er. Babban Yadav SHUATS

Agricultural Tractor Er. Babban Yadav SHUATS
Source: M&M online training

Agricultural Tractor Er. Babban Yadav SHUATS

Agricultural Tractor Er. Babban Yadav SHUATS
Problem:

A tractor engine develops brake power of 24 kW at 2000 rpm. When engaged in first gear, the
drive provides a gear reduction ratio of 40:1 through main gear box and 4:1 through final
differential unit. The overall transmission efficiency in first gear is 90%. Determine the torque,
speed and power at both the rear wheels. Assume tractor is moving on straight path.

Agricultural Tractor Er. Babban Yadav SHUATS

 Direction of travel

Nw=
50/4 = 12.5 rpm

Ne=
2000 rpm Np=
Pe= 24 kW 2000/40 = 50 rpm
Differential
4:1
Te= Gear box NeTe = ηNpTp
𝑃𝑒×60000 𝑁𝑒 𝑇𝑒
2𝜋×2000
40:1 Tp = η =
𝑁𝑝
= 114. 65 Nm 2000 × 114.65 Tw= 4127.38 × 4 =
0.90×
50
16509.52 Nm
= 4127.38 Nm
16509.52/2 = 8254 Nm
(on each wheel)
8254 ×2𝜋×12.5
Pw= = 10.80 kW
60000

Agricultural Tractor Er. Babban Yadav SHUATS

A 35 hp tractor has a four speed sliding gear box. The speed ratio of driving shaft to the driver
shaft are approx. 4:1, 2.5:1, 1.5:1 and 1:1 in the first, second, third and top gear respectively.
The pitch of gear in module is 3.72 mm and center to center distance between mating gears is
80 mm. Find the suitable number of teeth on the gears resulting in 1st, 2nd speed reduction.
Assume number of teeth on pinions on input shaft and counter shaft to be 14 and 29
respectively.

Agricultural Tractor Er. Babban Yadav SHUATS

 Case-1: 1st speed ratio of 4:1 (1-2-7-8)

𝑁1 𝑇2 ×𝑇8
=
𝑁8 𝑇1 ×𝑇7
6
1 4
4 29 ×𝑇8 8
Or, =
1 14 ×𝑇7
56 𝑇8 𝐷8
Or, = = 80
29 𝑇7 𝐷7

Again, D8 + D7 = 160 (Given)

Therefore, 56
D8 + 29 D8 = 160 7
2 5
3
D7 = 54.58
D8 = 105.4

T8 = 28
T7 = 15

Agricultural Tractor Er. Babban Yadav SHUATS

 Case-2: 1st speed ratio of 2.5:1(1-2-5-6)

𝑁1 𝑇2 ×𝑇6
= 6
𝑁6 𝑇1 ×𝑇5 1 4 8
2.5 29 ×𝑇6
=
1 14 ×𝑇5
35 𝑇6 𝐷6
= =
29 𝑇5 𝐷5
Again, D5 + D6 = 160 (Given)

D5 + (35/29)D5 = 160 7
2 5
160 ×29 3
D5 = = 72.5
64

D6 = 87.5

T5= 20
T6= 24

Agricultural Tractor Er. Babban Yadav SHUATS

Problem-3:

Find the gear ratio of final drive of a tractor if tractor has 1.2m rear
wheel and forward speed of 5 km/h. When the engine is running at
1000 rpm. Speed reduction ratios in gearbox and differential are 3:1
and 3.5:1 respectively.
 1.2 m

Direction of travel

Np=
Ne= 1000 rpm
1000/3 = 333.33 rpm Speed of crown Nc =
Differential
Gear box 333.33
= 95.23 rpm
3.5:1 3.5
3:1
Final Drive ?
Therefore, gear ratio
of FD =
RPM of wheel at speed of 5 km/h= 95.23
= 4.30:1
22.11
V = πDNw

5 ×1000
= 3.14×1.28 ×Nw Nw = 22.11 rpm
60
5×1000
Nw = = 22.11
60×3.14×1.2
Agricultural Tractor Er. Babban Yadav SHUATS