Module II - Transmission

MODULE –II
TRANSMISSION SYSTEM
CIJIL B. JOHN
Asst. Professor
Dept. of Mech. Engg.
Jyothi Engineering College,
Cheruthuruthy
Module –II- Syllabus
• Friction clutch:- fundamentals, driven plate inertia, driven plate
transmitted torque, driven plate wear –angular driven plate
cushioning and torsional damping, clutch friction materials, when
clutch is worn out.
• Pull type diaphragm clutch, multiple diaphragm clutch, multi-plate
hydraulically operated automatic transmission clutch, semi
centrifugal clutch, fully automatic centrifugal clutch, and integral
single plate diaphragm clutch.
• Need of gear box, resistance to vehicle motion, power to weight
ratio, speed operating range-five speed and reverse sliding mesh,
constant mesh, and synchromesh gear boxes:-gear synchronization
and engagement.
• Over drives – hydrodynamic fluid couplings: - efficiency and
torque capacity – fluid friction coupling- torque converters.
CIJIL B. JOHN/AP_ME/JECC 2
Transmission System
Transmission System refers to the whole mechanism used for transmitting

the power / torque from the engine crankshaft to the driving wheels.
Functions of transmission system
• At low speeds, the torque produced by the IC engine is very small,
which increases with increase in speed, peaks at an optimum speed and
then decreases beyond that rpm.
• If the engine is directly coupled to the road wheels, it may not have
enough torque to start the vehicle from rest.
• The vehicle demands large variation of power or torque at the road
wheels, depending on the running conditions. It would not be possible
to run the engine always at the optimum speed.
• A transmission system provides the means to vary the torque ratio b/w
the I.C engine & the wheelsCIJIL
whenever required.
B. JOHN/AP_ME/JECC 4
Functions of transmission system
• The transmission also provides a neutral position so that the engine

& the road wheels are disconnected even when the clutch is in the
engaged position.
• The transmission provides the means to back the car by reversing
the direction of rotation of the drive.
CLUTCH
A clutch is a device used in the transmission system to engage and
disengage the engine to the transmission.
CLUTCH
Functions of clutch
 Clutch is used to disengage and engage the engine with rest of the
transmission systems
 Intermediate mechanism which transmits power from the engine to
gear box.
 To couple the engine when and then is needed and give transmission to
the gear box unit.
 To disengage & engage while starting the engine and while changing
gear ratio.
 It prevents jerky motion of the vehicle
 The purpose of clutch is: In normal condition, the clutch remains
in the engaged position and allows flow of power from the engine
to the gear box.
 When we need to slow down the vehicle or to stop the vehicle or
during the gear changing period, clutch is disengaged; hence the
power to the gear box is cut-off.
 The clutch is operated by means of a foot operated clutch lever.
 When we apply the clutch lever, the pressure plate attached to the
clutch assembly is disengaged from the rotating flywheel and the
power transmission is cut off

Requirements of a clutch
 Transmit maximum torque of the engine.
 Engage gradually to avoid sudden jerks.
 Dissipate maximum amount of heat.
 Damp the vibrations and noise.
 Dynamically balanced.
 As small as possible.
 Easy to operate.
Types of clutch
1. Friction clutch
1. Single plate clutch
Direct engaging
2. Multi plate clutch clutches
3. Cone clutch
4. Dog and spline clutch
2. Centrifugal & Magnetic clutches

3 Hydraulic Clutch ( Fluid Coupling)
4. Torque converter
5. Diaphragm clutch
SINGLE PLATE (Coil Spring) CLUTCH
Single plate clutch
Clutch plate is held b/w the flywheel and the pressure plate.
depending upon design, the springs are arranged circumferentially.
These springs will provide axial force to keep the clutch in engaged
position. The friction plate is mounted on a hub. The hub is splined
from inside. So the hub is free to slide over the gearbox shaft. Friction
lining is attached to the friction plate on both sides. A pedal provided to
pull pressure plate against the spring force whenever it is required to be
disengaged.
Single plate clutch
When the clutch pedal is pressed, the pressure plate is moved
to the right against the force of the springs. Thus friction plate is
released and clutch is disengaged.
ADVANTAGES
1. Gear changing is easier than with the cone clutch.
2. More reliable
DISADVANTAGES
3. The springs must be more stiff.
4. Greater force is required by the driver while disengaging.
Single plate clutch
• Cars use Single plate clutch as there is enough space to use the
correct diameter plate to create the right amount of torque while
motorcycles use multi-plate clutches as they have limited space &
need to create more friction surfaces to produce the required torque.
Advantages of Single plate clutch
• Easy to repair
• Easy to transmit power.
Clutch Parts and Operation
• Clutch parts
– Flywheel
– Pressure plate
– Friction disc
– Release mechanism
• When Clutch disc pushed against flywheel with enough force;
– Disc will rotate with flywheel
Clutch Parts and Operation
Pilot bushing or bearing in center
of flywheel or crankshaft, supports
the end of input shaft
(friction disk) splined to transmission

Input shaft
(throw-out bearing
T/O bearing) allows
to push on rotating
clutch fingers
Bolted to Crank
Bolted to flywheel - Applies

the spring force to clamp the (clutch fork) pushes
friction disk to the flywheel T/O bearing to release
16
CIJIL B. JOHN/AP_ME/JECC rotating clutch
Clutch Unit
• Flywheel also acts as a driving
member
• Pressure plate is connected to

clutch cover assembly.
• Clutch Cover assembly is bolted to
the flywheel.
• Clutch springs placed between
Pressure plate & Cover plate, press
the Pressure plate against the
clutch plate.
• Thus Clutch plate is squeezed

between Flywheel & Pressure plate.
Clutch Disc/ friction
plate
• Characteristics
– Clutch hub: inner part of disc and has splines
– Torsional dampers: absorb shock
– Clutch disc has facings made of friction material
• Contain molded or woven asbestos
– Facings riveted to both sides of cushion plate
• Cushion plate is riveted to disc plate
Throw out Bearing (release bearing)
• Slides on transmission input shaft bearing retainer
Pressure Plate
Releases friction disk
from flywheel
Moves pressure
Plate right
T/O bearing
Pivots
Pressure Plate
• Pressure plate is a Cast Iron plate

– Part of cover assembly
• Cover assembly is bolted to the flywheel

– Clutch disc is wedged between pressure plate and flywheel
– Space between pressure plate and flywheel is less than thickness

of clutch disc
– Engine and transmission are physically connected when clutch
pedal released
Flywheels
• Add weight to crank for non-power strokes
• Has ring-gear for cranking engine (usually replaceable)
Single Plate Clutch - Applications
• Used where there is enough space to use the correct diameter plate
to create the right amount of torque – Cars.
Multi Plate Clutch
• Advanced form of the Single plate clutch – no. of frictional &

pressure plates are increased.
• As the no. of frictional surfaces are increased, the torque
transmitting capacity will also increase.
• Also, the overall diameter of the clutch is reduced for the same
torque transmission compared to a Single plate clutch.
• Used in racing cars & heavy vehicles where high torque is to be
transmitted & in Scooters, motor cycles, auto rickshaws etc.
Multi plate clutch
Pull type Diaphragm Clutch
Single Plate Diaphragm Clutch
Diaphragm V/s Plate Clutch
• Diaphragm clutch is similar to Single plate clutch

• The only difference is that in Diaphragm clutch, Diaphragm
Springs or Belleville Springs are used instead of ordinary springs
as in Single plate clutch.
Cone Clutch
Cone Clutch
• Uses 2 conical surfaces to transmit torque by friction.
• Consists of a female cone & male cone mounted on the driving & driven
shaft respectively.
• A friction lining (asbestos, leather) is introduced b/w the male & female
cone. A spring provides the necessary axial force to the male cone to press
against the flywheel.
• Cone transmits higher torque than plate or disc clutch of the same size
due to the wedging action & increased surface area.
• The normal force acting on the friction surface is greater than the axial
force, as compared with other clutches.
Cone Clutch
1. Racing Cars
2. Rally cars
3. Power boats
4. Extreme Off-road vehicles
Cone Clutch - Disadvantages
1. If the angle of Cone is made smaller than 20 deg., the cone

tends to bind with the flywheel & it becomes difficult to
disengage the clutch.
2. A small amount of wear on the cone surfaces result in a large
amount of axial movement of the male cone.
Centrifugal Clutch
• Uses centrifugal force to connect two concentric shafts, with the driving shaft
nested inside the driven shaft. It engages more at higher speeds.
• The input of the clutch is connected to the engine crankshaft while the output to
the transmission shaft.
• As engine RPM increase, weighted arms in the clutch swing outward and force
the clutch to engage.
• The most common types have friction pads or shoes radially mounted that
engage the inside of the rim of a housing. On the center shaft there are an
assorted number of extension springs, which connect to a clutch shoe.
• When the central shaft spins fast enough, the springs extend causing the clutch
shoes to engage the friction face. It can be compared to a drum brake in

reverse.
• The weighted arms force these disks together and engage the clutch.
• When the engine reaches a certain speed, the clutch activates,
working somewhat like a continuously variable transmission.
• As the load increases, the speed drops, disengaging the clutch,
letting the speed rise again and reengaging the clutch.
• If tuned properly, the clutch will tend to keep the speed at or near
the torque peak of the engine
• Centrifugal clutches are often used in mopeds, underbones, lawn
mowers, go-karts, chainsaws, mini bikes, and
some paramotors and boats.
Centrifugal Clutch
Hydraulically Operated Clutch
• Used in heavy duty applications where the force required to
disengage the clutch becomes excessive.
• Suitable for vehicles where clutch pedal & the clutch are kept too far
from each other.
• The pedal operates the piston of a master cylinder.
• The hydraulic pressure thus produced is transmitted to a slave
cylinder connected to the pressure plate.
• This fluid under P moves the piston of the slave cylinder which
further operates the clutch release fork & gets disengaged.
Hydraulically Operated Clutch - Advantages
1. Complicated clutch linkages are eliminated.

2. Vibration & wear of linkages are eliminated.
3. Reduces driver’s effort (by assisting hydraulically).
4. Long distance b/w pedal & clutch plate is possible without any
mechanical linkage.
5. Flexible turning of hydraulic line at any angle.
CLUTCH FRICTION MATERIALS
• Clutch friction linings are subjected to severe rubbing & heat
generation for a relatively short time period.
• The desirable properties are;
 Relatively high coefficient of friction.
 Relatively high energy absorption capacity for short period.
 Adequate shear stress to transmit engine torque.
 Capability of maintaining friction properties.
 Capable of withstanding centrifugal forces during gear changing.
CLUTCH FRICTION MATERIALS
• High degree of interface contamination tolerance without

affecting its friction & gripping characteristics.
• High level of cyclic working endurance without deteriorating
its friction properties.
REQUIREMENTS OF CLUTCH
1. Driven Plate Inertia
- Driven plate must have minimum possible weight so that it

produces minimum amount of spin when the clutch is disengaged.
- Clutch rotating parts should have minimum inertia.
-For rapid slowing down of the driven plate, the diameter,
Centre of gravity & the weight of the plate is to be kept minimum.
2. Driven Plate Transmitted Torque
- Clutch should be able to transmit the maximum torque of the

engine under all conditions.
- Torque capacity of a friction clutch increases with the
increase of Coefficient of friction of the rubbing materials, the diameter
& the spring thrust sandwiching the driven plate.
-Friction lining materials limit the coefficient of friction to the
order of 0.35.
3. Heat Dissipation
- A large amount of heat is generated during clutch application.

- Rubbing surfaces should have sufficient surface area & mass
so that they can absorb the heat generated.
-Proper ventilation or cooling for adequate heat dissipation
must be ensured while clutch design.
4. Gradual Engagement
- Clutch should positively take the drive gradually without occurrence

of sudden jerks.
6. Dynamic Balancing
- Dynamic balancing is essential particularly in case of high
speed clutches.
6. Size of the Clutch
- Must be as small as possible so that it should occupy a very less

amount of space .
7. Driven Plate Wear
-Wear b/w 2 rubbing surfaces is directly related to the energy

dissipation per unit area of contact surfaces,
- The lining life can be improved by increasing the no. of pairs of

rubbing surfaces.
- By doubling the surface area as in a twin plate clutch, the energy

input per unit lining area will be halved, which results in a 50% decrease in
facing wear.
- Small diameter multi plate clutches are usually preferred for high
performance cars.
8. Angular driven plate cushioning and Torsional damping
- Axial cushioning of the lining provides better clutch engagement

control, thereby prolonging the life of the friction faces.
- Improved distribution of friction work over the lining faces reduces

the peak operating temperatures & prevent lining fade, with the resultant
reduction in coefficient of friction & clutch slip.
RESISTANCE TO VEHICLE MOTION
• An engine must develop sufficient power to keep a vehicle moving by

overcoming the road resistances.
• Road resistance is called Tractive resistance.
• The propelling Thrust needed at the tyre to road interface to

overcome the resistances – Tractive effort.
• Road resistance is made up of;
1. Air/Wind resistance
2. Gradient resistance
3. Rolling resistance
1. AIR RESISTANCE
• Aerodynamic drag
• When a vehicle travels through a medium, the molecules of the
medium collide with the vehicle frontal area & absorbs some of its
energy.
• Depends mainly on;
1. Density of the medium

2. Speed of the object
3. Frontal area of the vehicle.
2. GRADIENT RESISTANCE
When a vehicle travels uphill, a component of its weight will work in a direction
opposite to its motion.
3. ROLLING RESISTANCE
• While rolling, a vehicle moves with its tyres in contact with the road
surface.
• Due to this relative motion b/w the surfaces, friction occurs which
opposes the vehicle motion.
POWER TO WEIGHT RATIO
Power-to-weight ratio =
• Power-to-weight ratio (or specific power or power-to-mass
ratio) is a calculation commonly applied to engines & mobile
power sources to enable the comparison of one unit or design
to another.
• Power-to-weight ratio is a measurement of actual
performance of any engine or power source.
The 2016 F1 cars have a power-to-weight ratio of 1,400 hp/t (1.05
kW/kg). Theoretically this would allow the car to reach 100 km/h (62
mph) in less than 1 second.
OX
EA RB
G
Automotive Gears: Gears play an important role in trucks,
car, buses, motor bikes and even geared cycles. These gears
control speed and include gears like ring and pinion, spiral gear,
hypoid gear, hydraulic gears, reduction gearbox.
•Depending on the size of the
vehicles, the size of the gears
also varies.
• There are low gears covering a

shorter distance and are useful
when speed is low.
•There are high gears also with

larger number of teeth.
Functions of Transmission
• To provide the high torque at the time of starting, hill climbing,

accelerating and pulling a load since high tractive effort is
needed
• It permits engine crankshaft to revolve at high speed, while the
wheels turn at slower speeds & vice versa.
• Variable torque can be obtained by set of gears.
• Vehicle speed can be changed keeping engine speed same with
certain limit
• The transmission also provides a neutral position so that the
engine and the road wheels are disconnected even with the
clutch in the engaged position
• A means to back the car by reversing the direction of rotation of
the drive is also provided by the transmission
Gear Ratio
Types of Transmission
 Manual Transmission
 Sliding Mesh Gear box
 Constant Mesh Gear box
 Synchromesh Gear box
 Automatic Transmission
o Over drive (semi-automatic)
o Fluid drive or Fluid coupling
o Fully automatic
 Epi-cyclic gear box
 Free Wheeling unit
 Torque Convertor
Manual & Automatic Transmissions
• Manual transmissions – called ‘Gear boxes’
• Mechanical efficiency in direct drive – 98%
• Simplicity, lower initial cost, requires less maintenance, increased fuel
efficiency.
• Engaging & disengaging the clutch, along with changing gears while
driving in traffic is quite tedious for the driver.
• Also creates an interruption of torque when the driver declutches to
change gears.
• To simplify the driving operations, modern vehicles employ automatic
transmission.
1. SLIDING MESH GEARBOX
• Driver has the choice of selection of gear ratio according to the
speed of the vehicle.
• Sliding mesh gear box uses ‘Spur gears’ for power transmission –
simplest type.
• 3 shafts are mounted for power transmission;
1. Primary / Clutch Shaft

2. Lay shaft
3. Main / Gear Shaft
Sliding mesh type of gear box
Sliding mesh type gear box
Velocity ratio : about 4:1
Velocity ratio: about

2.8:1
Speed ratio : about 1:1
2. CONSTANT MESH GEARBOX
• Most commonly used in modern automobiles.
• Main shaft gear wheels & lay shaft gear wheels are always engaged
(meshed) with each other.
• Uses ‘Double Helical Gears’ for transmission b’cos of its quieter
(non-noisy) operation.
• The gears on the main shaft are on bearings which permit them to
rotate freely.
• The connection b/w any of the gear wheels & the main shaft is
obtained by ‘Dog Clutch members’.
CONSTANT MESH GEAR BOX
3. SYNCHROMESH GEARBOX
• Similar to Constant mesh gearbox- gear wheels on the main shaft are
always in mesh with the gear wheels on the lay shaft.
• In addition, here a Synchromesh device is used.
• The parts to be engaged ultimately are first brought into frictional
contact which equalizes their speed, after which they may be
engaged smoothly.
• Reduces wear on the gear, easy gear shifting & quieter operation.
• High initial cost & complex design.
Fluid flywheel or Hydraulic Coupling
Fluid Coupling or Torque Convertor
A fluid coupling is a hydrodynamic device used to transmit

rotating mechanical power. It has been used in automobile
transmission as an alternative to a mechanical clutch
Fluid coupling consists of three components, plus the
hydraulic fluid:
The housing, also known as the shell (which must
have an oil tight seal around the drive shafts),
contains the fluid and turbines.
Two turbines:
 One connected to the input shaft; known as the pump or
impellor, primary wheel, input turbine, driving member
 The other connected to the output shaft, known as the turbine,
output turbine, secondary wheel or runner or driven member
• The driving turbine, known as the 'pump', (or driving torus) is rotated by
the prime mover, which is typically an internal combustion engine or
electric motor. The impellor's motion imparts both outwards linear and
rotational motion to the fluid.
• The hydraulic fluid is directed by the 'pump' whose shape forces the flow
in the direction of the 'output turbine' (or driven torus). Here, any
difference in the angular velocities of 'input stage' and 'output stage'
result in a net force on the 'output turbine' causing a torque; thus causing
it to rotate in the same direction as the pump.
• The motion of the fluid is effectively toroidal - travelling in one direction
on paths that can be visualised as being on the surface of a torus:
• If there is a difference between input and output angular velocities the
motion has a component which is circular (i.e. round the rings formed by
sections of the torus)
• If the input and output stages have identical angular velocities there is no
net centripetal force - and the motion of the fluid is circular and co-axial
with the axis of rotation (i.e. round the edges of a torus), there is no flow
of fluid from one turbine to the other.
The figure shows the power transmission system of an
automobile . The motion of the crank shaft is transmitted
through the clutch to the gear box. From the gear box the
motion is transmitted to the propeller shaft through the
universal joint and then to differential through another
universal joint. Finally power transmitted to the rear wheels
through the rear axle.

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MODULE –II

Transmission System refers to the whole mechanism used for transmitting

• The transmission also provides a neutral position so that the engine

to the gear box.

 When we need to slow down the vehicle or to stop the vehicle or

during the gear changing period, clutch is disengaged; hence the

power to the gear box is cut-off.

 The clutch is operated by means of a foot operated clutch lever.

clutch assembly is disengaged from the rotating flywheel and the

power transmission is cut off

2. Centrifugal & Magnetic clutches

(friction disk) splined to transmission

Bolted to flywheel - Applies

• Pressure plate is connected to

• Thus Clutch plate is squeezed

• Pressure plate is a Cast Iron plate

• Cover assembly is bolted to the flywheel

– Space between pressure plate and flywheel is less than thickness

• Advanced form of the Single plate clutch – no. of frictional &

• Diaphragm clutch is similar to Single plate clutch

1. If the angle of Cone is made smaller than 20 deg., the cone

nested inside the driven shaft. It engages more at higher speeds.

the transmission shaft.

the clutch to engage.

assorted number of extension springs, which connect to a clutch shoe.

shoes to engage the friction face. It can be compared to a drum brake in

1. Complicated clutch linkages are eliminated.

• High degree of interface contamination tolerance without

- Driven plate must have minimum possible weight so that it

- Clutch should be able to transmit the maximum torque of the

- A large amount of heat is generated during clutch application.

- Clutch should positively take the drive gradually without occurrence

6. Size of the Clutch

- Must be as small as possible so that it should occupy a very less

-Wear b/w 2 rubbing surfaces is directly related to the energy

- The lining life can be improved by increasing the no. of pairs of

- By doubling the surface area as in a twin plate clutch, the energy

- Axial cushioning of the lining provides better clutch engagement

- Improved distribution of friction work over the lining faces reduces

• An engine must develop sufficient power to keep a vehicle moving by

• The propelling Thrust needed at the tyre to road interface to

1. Density of the medium

• There are low gears covering a

•There are high gears also with

• To provide the high torque at the time of starting, hill climbing,

1. Primary / Clutch Shaft

Velocity ratio : about 4:1

Velocity ratio: about

Speed ratio : about 1:1

• Most commonly used in modern automobiles.

A fluid coupling is a hydrodynamic device used to transmit

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