Triple-Ratio Power Transmission System

Triple-Ratio Power Transmission System

This mechanical design exercise realizes a three-speed manual transmission gearbox suitable for light automotive or educational demonstration purposes. The gear train consists of input, counter, and output shafts arranged in a constant-mesh configuration, with dog clutches selecting among three distinct gear ratios. Spur gears are designed using Lewis and Buckingham equations to ensure bending and surface durability under rated torque loads. The housing is fabricated from aluminum alloy to minimize mass while maintaining stiffness. A comprehensive CAD model, finite element stress analysis of critical shafts, and physical prototype validate the theoretical calculations. The project encompasses lubrication system design, bearing selection based on L10 life criteria, and shift mechanism ergonomics.

Components

Mild Steel Shafts
Spur Gears (Set)
Aluminum Housing
Ball Bearings
Dog Clutches
CAD Software