Assignment

Name: Jahanzeb
Roll No: 0032-Bsc.Engg-EE-21
Subject: Basic Mechanical Engineering
Semester: 5th
 Gears
Definition:
A gearbox, also known as a gear drive, has three main functions:
1. to increase torque from the driving equipment (motor) to the driven
equipment
2. to reduce the speed generated by the motor
3. to change the direction of the rotating shafts.

The connection of this equipment to the gearbox can be accomplished

using couplings, belts, chains, or hollow shaft connection

Speed and torque are inversely and proportionately related when power
is held constant. Therefore, as speed decreases, torque increases at the
same ratio.

Types of Gears
Spur gear:

Spur gears transmit power through shafts that are parallel. The teeth of
the spur gears are parallel to the shaft axis. This causes the gears to
produce radial reaction loads on the shaft, but not axial loads. Spur gears
tend to be noisier than helical gears because they operate with a single
line of contact between teeth. While the teeth are rolling through mesh,
they roll off of contact with one tooth and accelerate to contact with the
next tooth. This is different than helical gears, which have more than
one tooth in contact and transmit torque more smoothly.
Helical Gear
Helical gears have teeth that are oriented at an angle to the shaft, unlike
spur gears which are parallel. This causes more than one tooth to be in
contact during operation and helical gears can carry more load than spur
gears. Due to the load sharing between teeth, this arrangement also
allows helical gears to operate smoother and quieter than spur gears.
Helical gears produce a thrust load during operation which needs to be
considered when they are used. Most enclosed gear drives use helical
gears.

Double Helical Gear

Double helical gears are a variation of helical gears in which two helical
faces are placed next to each other with a gap separating them. Each
face has identical, but opposite, helix angles. Employing a double helical
set of gears eliminates thrust loads and offers the possibility of even
greater tooth overlap and smoother operation. Like the helical gear,
double helical gears are commonly used in enclosed gear drives

Herringbone Gear
Herringbone gears are very similar to the double helical gear, but they
do not have a gap separating the two helical faces. Herringbone gears
are typically smaller than the comparable double helical and are ideally
suited for high shock and vibration applications. Herringbone gearing is
not used very often due to their manufacturing difficulties and high cost.

Bevel Gear
Bevel gears are most commonly used to transmit power between shafts
that intersect at a 90 degree angle. They are used in applications where
a right angle gear drive is required. Bevel gears are generally more costly
and are not able to transmit as much torque, per size, as a parallel shaft
arrangement.
Worm Gear
Worm gears transmit power through right angles on non-intersecting
shafts. Worm gears produce thrust load and are good for high shock load
applications but offer very low efficiency in comparison to the other
gears. Due to this low efficiency, they are often used in lower
horsepower applications

Hypoid Gear
Hypoid gears look very much like a spiral bevel gear, but unlike spiral
bevel gears, they operate on shafts which do not intersect. In the hypoid
arrangement because the pinion is set on a different plane than the
gear, the shafts are supported by the bearings on either end of the shaft.
 Rexnord
Industries Applications
Products

Food Small conveyors

Beverage Package handling
Automotive equipment
Spur Gear PP Plant Gear
Forest Farm machinery
Energy Planetary gear sets
Unit handling Automotive

Cement
Food
Medium to large conveyors
Beverage V-Class
Mixers
Mining Quadrive
Helical Gear Large pumps
Marine UltraMax
Water treatment
Energy Ultramite
Crushers
Forest
Bulk material handling

Mining Milling
Double Helical
Gear Marine Steam turbines
Heavy industry Ship propulsion

Mining Milling
Herringbone Gear Marine Steam turbines
Heavy industry Ship propulsion

Cement
Food Medium to large conveyors
Beverage Mixers V-Class
Bevel Gear
Mining Crushers Ultramite
Energy Water treatment
Bulk material handling

Food
Beverage Small conveyors
Automotive Package handling Ultramite
Worm Gear
Forest equipment Omnibox
Energy Farm machinery
Unit handling
Hypoid Gear Cement Small to medium conveyors
Food Small mixers
Beverage Crushers
 Mining
Energy Water treatment
Bulk material handling

Shaft
A shaft is a rotating member, usually of a circular cross-section, either
solid or hollow, which transmits power and rotational motion.

What are mechanical shafts?

A mechanical shaft is a mechanical power transmission element, usually

circular in cross-section, either solid or hollow, which transmits torque
and rotational motion from one device to another.

shaft-design

Machine elements such as gears, pulleys, flywheels, clutches, and

sprockets are mounted on various shaft types and are used to transmit
power from the driving device, such as a motor or engine. A vehicle
crankshaft is a prime example of a mechanical shaft, as shown in the
above figure.

Types of shafts
Mechanical shafts are broadly categorized into the following four types.

 Transmission shaft – The transmission shaft is one of the essential

machine components that provides the axis of rotation and
oscillation and regulates the motion geometry.

 Axle shaft – An axle is a non-rotating version of a shaft that

supports rotating pulleys and wheels but carries no torque. An
axle is a static beam and can be analyzed as one supported beam

 Spindle shaft – A spindle is a revolving shaft with a fixture for

retaining a tool (or workpiece in the case of milling, grinding, or
drilling spindle) (in the case of a turning spindle). The spindle shaft
is a tool or workpiece support, positioner, and rotational drive

 Machine shaft – These shafts are an inherent element of the

machine and are located inside the assembly. A crankshaft of an
automobile engine is an example of a machine shaft

Clutch
Definition
A clutch is a mechanical device used in vehicles and machinery to engage
or disengage power transmission between two rotating components,
typically an engine and a gearbox. It enables smooth gear changes and
control over the power transfer, allowing the operator to stop or change
the vehicle's motion without turning off the engine.
Clutch Construction with Components
A clutch consists of several key components: the clutch disc, pressure
plate, flywheel, and release bearing. The clutch disc is sandwiched
between the pressure plate and the flywheel. When engaged, the
pressure plate applies pressure to the clutch disc, allowing power
transfer. When disengaged, the pressure is released, interrupting the
power flow.

The various components of Clutch include:

1. Flywheel
2. Friction Disc
3. Pressure Plate
4. Spring
5. Release levers
6. Clutch release bearing and Linkage

Flywheel
The flywheel serves as an energy storage component that efficiently
stores excess energy and releases it back into the system when needed.
It is typically connected to the crankshaft and continues to rotate as long
as the engine is running. The flywheel incorporates a friction surface,
also referred to as a friction disc, which is securely fastened to its outer
side. This friction disc enables smooth engagement and disengagement
of the power transmission, providing a controlled interface for
transferring power between the engine and other components. By
effectively storing and releasing energy, the flywheel contributes to
maintaining consistent operation and optimal performance in various
mechanical systems.

Friction Disc
Clutches commonly feature single or multiple discs that are lined with
friction material possessing a high coefficient of friction. These discs are
mounted on the driven shaft and play a vital role in enabling directional
changes between the driving and driven shafts. The friction generated
between the discs facilitates this transfer of power. Additionally,
clutches often consist of metal plates that are bonded together, further
enhancing their structural integrity and durability. These metal plates
contribute to the overall strength and stability of the clutch assembly,
ensuring reliable and efficient power transmission in various mechanical
systems.

Pressure Plate
The primary purpose of a clutch is to serve as a crucial link between the
engine and gearbox, facilitating the transmission of torque from the
engine to the gearbox. In this process, another friction disc is securely
attached to the pressure plates. The pressure plate, in turn, is mounted
on the spline hub, creating a cohesive assembly. This arrangement
allows for controlled engagement and disengagement of the power
transmission, enabling smooth shifting of gears and efficient transfer of
torque from the engine to the gearbox. The combination of friction
discs, pressure plates, and the spline hub ensures reliable and precise
power transfer within the clutch mechanism.

Spring and Release Levers

Diaphragm springs are commonly used in clutches to provide the
necessary spring force. The operation of these springs is facilitated
through the use of levers. The release lever plays a crucial role in
relieving the force exerted on the spring when the clutch is disengaged.
By activating the release lever, the tension on the diaphragm spring is
reduced, allowing for smooth disengagement of the clutch mechanism.
This ensures proper clutch operation and enables seamless transitions
between engaged and disengaged states, enhancing the overall
performance and functionality of the clutch system.

Clutch Release Bearing

The transmission of movement from the clutch linkage to the pressure
plate is typically facilitated by a ball or roller type bearing. This bearing
serves as a pivotal component, allowing for smooth and efficient
operation of the clutch assembly. Moreover, the bearing is designed to
be self-centering, meaning it can automatically adjust and compensate
for any variations or misalignments in the clutch system. This self-
centering feature ensures that the pressure plate remains properly
aligned and engaged with the friction discs, promoting optimal clutch
performance and longevity.

Linkage
A clutch linkage mechanism utilizes a combination of levers and rods to
transfer motion from the pedal to the fork. When the clutch pedal is
pressed, the pushrod is activated, pushing the bell crank and causing a
reverse movement in the pedal. The bell crank, in turn, is connected to
the release rod.

The release rod plays a crucial role in transferring the movement from
the bell crank to the fork. It serves as a linkage between the pedal and
the clutch fork, enabling the engagement and disengagement of the
clutch mechanism. Additionally, the release rod allows for the
adjustment of the clutch, ensuring proper operation and optimal clutch
performance. By providing a means of adjustment, it facilitates fine-
tuning of the clutch engagement point, enhancing the overall control
and functionality of the clutch system.

Belt
Definition:
A belt drive is a frictional drive that transmits power between two or
more shafts using pulleys and an elastic belt. In most cases, it is powered
by friction but it may also be a positive drive. It can operate at wide ranges
of speed and power requirements. It is also highly efficient.
When it comes to cost, a belt drive is considerably cheaper than gear
and chain drives. It costs less to install as well as maintain. Belt drive
sheaves or pulleys undergo little wear compared to chain drive sprockets
over extended periods of use.

Contrary to most chain and gear drives, a belt drive can handle some
degree of misalignment. Correct alignment, however, increases service life.
Excessive misalignment is responsible for issues such as improper belt
tracking, uneven pulley wear, noisy operation and belt edge wear. The
intensity of these issues is directly proportional to the belt’s width.

Belt Tension and Slack

The belt is subjected to tension when the driving pulley pulls it. This belt
tension, in addition to the static belt tension, is responsible for the transfer
of mechanical force. High belt tension prevents heat buildup, slippage and
alignment problems as there is little to no relative motion between the belt
and the pulleys. On the other side, the driving pulley pushes the belt away
towards the driven pulley. This causes slacking of the belt. Thus, a belt drive
sets up fluctuating loads in the belt. If these loads are not considered in
the design process, premature belt failure can occur. Fatigue is responsible
for more belt failures than any other issue.

It is easy to identify the slack side from the side under tension. Whichever
side of the belt approaches the driving pulley is under tension. The other
side is the slack side.

Types of Belt Drives

We can classify belt drives into seven main types, these are:
 Open belt drive
 Closed or crossed belt drive
 Fast and loose cone pulley
 Stepped cone pulley
 Jockey pulley drive
 Quarter turn belt drive
 Compound belt drive