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Sample Calculations For FNR Gear Box and CVT

The document provides sample calculations for selecting gear ratios and shaft dimensions for a gear box and CVT combination for an off-road vehicle. It calculates power requirements based on factors like wheel resistance, air resistance, gradient resistance and acceleration resistance. It then determines a gear reduction requirement of 8.68 based on these calculations. The document also includes proposed gear dimensions and modules, as well as shaft strength analysis based on applied torques and bending moments.

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Srijan Verma
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264 views

Sample Calculations For FNR Gear Box and CVT

The document provides sample calculations for selecting gear ratios and shaft dimensions for a gear box and CVT combination for an off-road vehicle. It calculates power requirements based on factors like wheel resistance, air resistance, gradient resistance and acceleration resistance. It then determines a gear reduction requirement of 8.68 based on these calculations. The document also includes proposed gear dimensions and modules, as well as shaft strength analysis based on applied torques and bending moments.

Uploaded by

Srijan Verma
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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org

SAMPLE CALCULATIONS FOR FNR GEAR BOX AND CVT COMBINATION

Gear Reduction Selection

Power Requirements against:

Fr: Wheel Resistance


FL : Air resistance
Fs: Gradient resistance
Fa: Acceleration resistance

Wheel Resistance= Rolling resistance + Slip Resistance + Road Resistance


Tr: Brake Torque

Assumption taken

Unmade road coefficient of friction fr= .16


mass of vehicle being=Mf

CALCULATIONS

Fr=fr*Mf*g*Cosst where st=30

Fr=0.16*200*9.81*Cos 30
Fr=280N

Total Load R=113kg(driver)+200kg (vehicle)


R=313*9.81=3070.50N

Static Resistance=R
=0.65*3070.5=1995.84N

Vmax=60kmph
Wheel Radius r=221.875mm
= .221m
Air Resistance

FL:0.5CwAv2
=Air Density

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Cw=Drag Coefficient
A=Area
V=velocity

FL =0.5*1.99*0.0315*(16.66)2
=0.52N

Gradient Resistance:
Fst=Mf*g *Sinst

Putting the corresponding value


Fst=131.725N

Acceleration resistance:
Fa=m*a
=956N
Ftotal=2662.247

Power Required: Ftotal*v/(Nrpm*)

Fig62: Gear Train Layout


=10Kw
Engine Torque Te=60000*7.084/(2*3800)
=17.81Nm
For low end gear=8.6*.85*17.81=130.2Nm
Tractive Effort=Tw/r=465.9N

Gear reduction requirement

Ia max; r*Mf*g(frCosst+Sinst)/Tmax*tot
Putting the values: 24.5
Ia min:2.77
Ioverall:24.5/2.77=8.68

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Proposed gear layout


Velocity At Lower And Higher end Gear ratio:V=16.28*(D/G)

V for High torque=14.37kmph


V for low torque=80kmph (theoretical)
Calculation for module and strength

Step1:Estimation of module based on beam strength

Zp=18
Zg=iZp=3.33*(18)
=60
Mt=60X106 *7.08/(2*3600)
=18.7Nm
Lewis form factor is 0.308 for 18 teeths
Therefore Y=0.308
Cs=Starting torque/rated Torque=1.5

Assuming a trial velocity value=5m/s


Cv=3/3+v=3/8

Assuming b/m=10

m={60X106[7.08*1.5*1.5*720*0.308]1/3}
{[18*3600*(3/8)*10*3]}
=2.5
=3mm

Step2 m=3mm
Dp=m*Zp=3(18)=54mm
Dg=m*Zg=180mm
b=10m=30mm

Checking the design


2Mt/Dp=695.5N
V=Dp*np/(60X103)=10m/s Cv=3/3+V=.2307

Peff=Cs/Cv*(Pt)
=4522.49N
From Lewis Equation, Sb=m*b*b*Y
=6642.8N
FOS=Sb/Peff=1.5

Step 3 Surface hardness for the pinion

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Q=2Zg/Zg+Zp=1.5 , Sw=bQDpK=30(1.5)(54)(0.16)(BHN/100)2
Sw=Peff(1.5)
=4522.5*1.5=6783.75=388.8(BHN/100)2
Or BHN=417

Now Centre to Centre Distance

a=m(Zp+Zg)/2=117mm =20
m=3mm, Addendum=m=3mm
Deddendum=1.25m=3.75mm
Clearance=0.25m=0.75mm
Working Depth=2m=6mm
Whole Depth=6.75mm
Tooth thickness=1.5m=4.712mm

SHAFT ANALYSIS(input/intermediate)

Fig 63:Shaft Analysis

Outer Diameter=19mm
Syt=460N/mm2 FOS=3

Centre to Centre=200mm Engagement Load=0.850KN, Maximum Load=1.2KN


=0.3 =180 P=7.084KW N=3600rpm
D=198mm Dp=54mm Kb=Kt=1.5

Step1 Permissible Shear Stress

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0.30(Syt)=138N/mm2
0.18(Sut)=0.18*700=126N/mm2 the lower of the two is 126N/mm2 max
=0.75(126)=94.5N/mm2

Step 2:Torsion Moment


Mt=60X106/2N=18660.91N or 44881.693N@1800rpm Step 3: Bending
Moment
Pulley Diameter =198mm

Pr=Pt*tan(20)
(P1-P2)X198/2=44881.693N
(P1-P2)=453.35N

And P1=3P2
Therefore 2P2=188.49N
P2=226.67N
P1=680.02N

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