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    Design Project 2 Auto Tranny

    Uploaded by

    Unmil Patel
    This document describes the design of a planetary gear train for the first gear set (P1) of a 5-speed automatic transmission. It includes calculations for determining the tooth counts of the sun, planet, and ring gears based on achieving a desired gear ratio while meeting fatigue life and stress requirements. Equations for calculating load, torque, stress, and fatigue life are provided. The designer must select a vehicle, calculate duty cycle and load profiles, then size the P1 gears to withstand the equivalent loads over 250,000 miles of operation while meeting stress and fatigue limits. Design details like material selection and a schematic will be reported.

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    Design Project 2 Auto Tranny

    Uploaded by

    Unmil Patel
    106 views9 pages
    This document describes the design of a planetary gear train for the first gear set (P1) of a 5-speed automatic transmission. It includes calculations for determining the tooth counts of the sun, planet, and ring gears based on achieving a desired gear ratio while meeting fatigue life and stress requirements. Equations for calculating load, torque, stress, and fatigue life are provided. The designer must select a vehicle, calculate duty cycle and load profiles, then size the P1 gears to withstand the equivalent loads over 250,000 miles of operation while meeting stress and fatigue limits. Design details like material selection and a schematic will be reported.

    Original Description:

    Automatic Transmission Project

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    This document describes the design of a planetary gear train for the first gear set (P1) of a 5-speed automatic transmission. It includes calculations for determining the tooth counts of the sun, planet, and ring gears based on achieving a desired gear ratio while meeting fatigue life and stress requirements. Equations for calculating load, torque, stress, and fatigue life are provided. The designer must select a vehicle, calculate duty cycle and load profiles, then size the P1 gears to withstand the equivalent loads over 250,000 miles of operation while meeting stress and fatigue limits. Design details like material selection and a schematic will be reported.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    106 views9 pages

    Design Project 2 Auto Tranny

    Uploaded by

    Unmil Patel
    This document describes the design of a planetary gear train for the first gear set (P1) of a 5-speed automatic transmission. It includes calculations for determining the tooth counts of the sun, planet, and ring gears based on achieving a desired gear ratio while meeting fatigue life and stress requirements. Equations for calculating load, torque, stress, and fatigue life are provided. The designer must select a vehicle, calculate duty cycle and load profiles, then size the P1 gears to withstand the equivalent loads over 250,000 miles of operation while meeting stress and fatigue limits. Design details like material selection and a schematic will be reported.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 9

    EML 3005: Mechanical Design

    Planetary Gear Train Fatigue Design for an Automatic Transmission


    Nagaraj K. Arakere
    Group Project 2 (17th Nov 2016 )
    Group Design Project Presentations: Nov 29-Dec 6. Report due on or before Dec 6.
    Automatic transmissions (Figure 1 shows a schematic of a 6-speed automatic automobile
    transmission) use planetary gear trains for achieving different gear ratios between the input (from
    the torque converter or fluid coupling) and the output shaft. This transmission uses 3 planetary
    gear trains (P1, P2, P3) and 5 clutch packs (C1-C5 in the 2nd figure below) to achieve 6 forward
    gear ratios and 1 reverse gear ratio.

    Clutch'C1'

    'C2'

    'C3'

    'C4'

    !P2!

    'C5'

    !P1!

    !P3!
    Fig. 1 Schematic of an automatic transmission
    1

    The following videos are recommended for understanding the operation of an automatic
    transmission.
    2D animation
    https://www.youtube.com/watch?v=Ugao6jTyM7k
    3D animation
    https://www.youtube.com/watch?v=u_y1S8C0Hmc
    3D
    https://www.youtube.com/watch?v=YYr1gx_FdkY
    Allison Truck Auto tranny
    https://www.youtube.com/watch?v=1ByVBBfEXWk
    https://www.youtube.com/watch?v=v4AJ2BvUMG4

    The basic equation for solving the output motion of any planetary gear train is (Eq. 13-32):

    For our purposes, ! = ! = , ! = ! = (),


    ! = ! = . The train value is given by e.

    e=

    nR nC
    nS nC

    (1)

    First Gear
    First gear is achieved by applying clutches C1 and C5. In the video the first gear ratio is given as
    3.10. This means 3.1 rotations of the input shaft will result in one rotation of the output shaft.
    The output shaft is always the planet carrier, shown in red. The input and output shafts turn in the
    same direction (clockwise looking into the left end).
    When ring gear is fixed and sun gear is input, the planer carrier speed (output), the gear ratio for
    this configutation is (refer to class notes)

    mG1 = 1+

    NR
    d
    NR
    = 1+ R = 3.1 or
    = 2.1
    NS
    dS
    NS

    (2)

    NR and NS are the number of teeth on the ring and sun gears, respectively. The gear pitch
    diameter is d. Because of geometry,

    d R = d S + 2d P ; Hence, N R = N S + 2N P
    (3)
    Using (2) and (3) we get we get
    2

    N P = 0.55N S ; d P = 0.55d S
    The following tooth numbers satisfy the conditions (not an unique solution):

    N P = 31, N S = 56, N R = 118


    This results in a gear ratio of 3.107 for first gear, since we must have integer number of teeth.

    mG1 = 1+

    NR
    118
    = 1+
    = 3.107
    NS
    56

    For one rotation of input gear (clockwise is negative) the output will rotate -1/3.107 = -0.3218
    revolutions.

    Second Gear
    3

    Second gear is achieved by applying clutches C1 and C4. This results in the 2nd planet carrier
    spinning with the gear rato of 3.107 (same as in first gear) or will rotate 1/3.107 = 0.3218
    revolutions for 1 revolution of input gear. The carrier of 2nd planetary system is connected to the
    ring gear of 1st planetary, which will speed up the output shaft, resulting in a faster 2nd gear.

    " 56 % " 31 %
    e = $ '$
    ' = 0.4745 = Train value
    # 31 & # 118 &
    We re-use Eq(1) as follows (assume sun gear input speed is at 1 rpm)

    0.4745 =

    0.3218 nC
    1 nC

    Solving for planet carrier speed, we get

    nC = 0.54; 2nd gear ratio = mG 2 = 1/ 0.54 = 1.851


    This means for 1.851 rotations of the input gear the output shaft will rotate once.

    Third Gear
    Third gear is achieved by applying clutches C1 and C3. This results in the carrier of the 3rd
    planetary rotating at 1/3.107 = 0.3218 revolutions for 1 revolution of input gear. The carrier of
    3rd planetary system is connected to the ring gear of 2ndt planetary (same as 2nd gear). This will
    result in the ring gear of the 1st planetary to spin at -0.54 rotations for -1 input shaft rotation
    (same as 2nd gear). Further the carrier of the 2nd planetary is connected to the ring gear of the 1st
    planetary. This will speed up the output shaft in two stages, resulting in a faster 3rd gear.
    From 2nd gear we know that the ring gear (brown carrier) will rotate -0.54 revolutions for -1
    rotation of input gear. Therefore

    0.4745 =

    0.54 nC
    1 nC

    Solving for planet carrier speed, we get

    nC = 0.6880; 3rd gear ratio = mG3 = 1/ 0.6880 = 1.453


    This means for 1.453 rotations of the input gear the output shaft will rotate once.

    Fourth Gear
    Fourth gear (direct drive or 1:1 gear ratio) is achieved by applying clutches C1 and C2. This
    results in a direct lockup (ring and sun gears have to spin at the same speed) with input and
    output speeds being same.

    Fifth Gear (overdrive)


    Fifth gear is achieved by applying clutches C2 and C3. Note that the blue shaft is NOT
    connected to input, and its RPM is decided by the 2nd planetary whose carrier is rotating at input
    speed. The ring gear of the 1st planetary is spinning at input speed. Input speed is taken to be -1
    RPM (clockwise) as before.
    Stage 1 calculation (2nd planetary)
    From 2nd gear we know that the ring gear (brown carrier) will rotate at -0.54 RPM. Note that the
    p

    0.4745 =

    0.3218 (1)
    nS (1)

    Solving for sun gear rpm, we get

    nS = 2.429
    This will be the input to the 1st planetary sun gear along with the ring gear rotating at input speed
    of -1 rpm.

    Stage 2 calculation (1st planetary)


    Here the ring gear is rotating at -1 RPM and sun gear at -1.9694 rpm. We need to find the output
    or planet carrier speed.

    0.4745 =

    1 nC
    2.429 nC

    Solving for planet carrier or output rpm, we get

    nC = 1.46; 5th gear ratio = mG5 = 1/ 1.46 = 0.685


    This means for 1.0 rotation of the input gear the output shaft will rotate 1.46 revolutions
    (overdrive, or output shaft spins faster than input shaft).

    Planetary Gear Design


    This project involves designing a 5-speed automatic transmission gearbox. This project involves
    designing the gears of only the first planetary gear train (P1), based on fatigue life, and
    bending and contact stress requirements. P1 gears go through the most cycles since they are
    loaded no matter which gear is engaged. Hence gears of P1 are the most critical componets in the
    transmission. Assume they are SPUR gears, for simplicity.You will select a car out of the article
    I have shown in class. You are required to write a detailed report detailing your gearbox design.
    The design report must present, at a minimum, the following information:
    Car selection, details such as weight, external dimensions, tire size, etc.
    Engine details (HP, torque ratings)
    7

    Drag coefficient, car frontal area calculations, estimated top speed. The Car &
    Driver article gives you drag forces measured in a wind tunnel. We can use that to
    calibrate your wind drag calculations.
    Equations used for calculating wind drag and rolling resistance, to calculate HP
    required at various speeds.
    Gear ratios selected for the 5-speed transmission, axle ratio selected. We will
    ignore the 6th speed since top speed is achieved in 5th gear.
    Duty cycle selected for the gearbox design. Explain why you selected the speed
    and mileage requirements. Design the gearbox for at least 250,000 miles. Select a
    fairly large number of miles at the top speed, to adequately load the gearbox.
    Make sure, based on your calculated HP requirements, that the car can indeed
    reach those speeds.
    Explain reason behind selection of the base point used for equivalent load
    calculations.
    Show all calculations pertaining to calculating numer of teeth for sun gear, planet
    gears and ring gear for P1. Remember that numer of teeth has to be an integer!

    Fatigue Life Calculations


    The SUN GEAR of P1 will experience the most number of fatigue cycles (since there are 3
    gear meshes for it). The planet gears are idler gears and experience double sided loading and
    may be more critical than the sun gear. Whichever gear has the largest face width will be the
    design face width (other gears will have this face width). Details of the equivalent torque
    calculations and Neq should be presented in detail. Clearly indicate the baseline condition chosen.
    Units for all variables must be clearly indicated. A table such as shown below should be
    included. See example posted.
    Cycle

    Gear
    Ratio

    Speed
    (mph)

    Miles

    Hours
    Spent

    RPM
    @Input
    Shaft

    HP
    @
    Input
    Shaft

    Torque
    @ Input
    Shaft
    (In-lb)

    Wt
    @ P1
    (Lb)

    1
    2
    3
    N
    Discuss selection of gear material, heat treatment and finishing requirements.
    A scaled line drawing (schematic) of the gearbox (P1) should be presented.

    Summary of the gearbox design details should be presented in a tabular form, an example of which is given below.

    Pitch Diameter, in
    Number of Teeth
    Normal Pressure Angle,
    Pd, Diametral Pitch
    Addendum, a, in (=1/Pd)
    Dedendum, b, in (=1.25/Pd)
    Qv, Quality factor
    V, ft/min
    Kv, Velocity factor
    Sc (Contact fatigue strength, ksi)
    St (Bending fatigue strength, ksi)
    Sy (Yield strength, ksi)
    Teq (Contact, in-lb)
    Teq (Bending, in-lb)
    HPeq (contact)
    HPeq (bending)
    Neq (Equivalent fatigue cycles)
    Life required, from duty cycle (hours)
    Wt (contact, lb)
    Wt (bending, lb)
    Wt (Max Torque considerations, lb)
    YN (life factor for bending)
    ZN (life factor for contact)
    all (allowable bending stress, ksi)
    c,all (allowable contact stress, ksi)
    Fc (face width based on contact stress, in)
    Fb (face width based on bending stress, in)
    Fc,accel (Max Torque - contact stress, in)
    Fb,accel (Max Torque - bending stress, in)
    Fdesign (design face width, in)
    bending (Use Fdesign, Teq-ben, ksi)
    YN (= bending /St)
    contact (Use Fdesign, Teq-con, ksi)
    ZN (= contact /Sc)
    FOS (bending = all /bending)
    FOS (contact = c,all /contact)
    Design Life (using Fdesign, contact, hours)
    Design Life (using Fdesign, bending, hours)
    Design Life (using Fdesign, contact, cycles)
    Design Life (using Fdesign, bending, cycles)
    Contact Ratio

    Sun Gear

    Planet
    Gear

    Ring Gear

    Ns

    NP

    NR

    N/A
    N/A

    N/A
    N/A
    N/A
    N/A

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