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SEQUENTIAL MANUAL GEARBOX UNIVERSITY OF BOLTON.MSP4002 VEHICLE SYSTEMS.6TH AND 7TH OF MAY 2015.JAMES AUGUSTUS.

AKINWUMIJU BENJAMIN OLUWASEGUN 20277275.

FD. MOTORSPORTS TECHNOLOGY.

ABSTRACT.4.1 Shaft.

4.2 Dog clutch.

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4.3 Gear selector rod.

4.4 The straight cut gear.

5.1 The processes used in gear production.

(1) The Casting.

(2) The Forging.

(3) Extrusion.

(4) Power Metallurgy.

(5) Blanking.

5.2 Materials to be considered in gear production.

(1) Low Efficient of Friction.

(2) Endurance strength & must withstand dynamic loads.

(3) High tensile strength and prevent failure against static loads.

(4) Good Manufacturability.

6.1 The forms of steel used in manufacturing Gears and Shafts in the Gearbox.

7.1 The Advantages and Disadvantages of Gears.

8.1 Appendixes and Images.

TABLE OF CONTENT.

(1) ABSTARCT. (Page 2).

(2) INTRODUCTION. (Page 4).

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(3) THE MAIN BODY. (Page 4, 5 & 6).

(4) ADVANTAGES AND DISADVANTAGES (page 7)

(5) CONCLUSION. (Page 8).

(6) APPENDICES. (Page 9, 10, & 11).

INTRODUCTION.A sequential manual gearbox is a non-traditional type of manual transmission used on most high-performance cars for auto racing, whereby the gears are selected in order, with traditional manual transmissions, the driver can move from gear to gear, by moving the shifter to the appropriate position. The gearbox works by shifting the

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lever when the clutch is been released in order to allow the gears to come into contact then spline together on the selector rod holding them in position, then the clutch will have to be released before selecting into another gear. Sequential manual transmissions works by providing the driver with the ability to select the gear directly before or after the gear currently engaged. Usually the shift lever is pulled back to select the adjacent higher gear and pushed forwards to select the adjacent lower gear. Beyond the ease of use from a driver's standpoint, an additional benefit of sequential manual gearboxes is that use of the clutch via foot pedal or hand control can be minimized, with the clutch only used for starting from a complete stop.

THE MAIN BODY.

The name of the gearbox was Trans Axle sequential gearbox (SLR 82-14 SADEV) which was a sealed up type, it has two outlet at the rear side in which the shaft is meant to have a connection with the output. At the top right side of the gearbox is a

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sensor connected to the gearbox and also other by the mid left side. On each sides of the gearbox are four Gear Mountains used in mounting the gearbox to the chassis with bolts.

The practical exercise was done by stripping down the gearbox, starting by opening the front casing which serves as cover rightly placed in front of the gearbox that houses the main functioning component in the gearbox.

The gearbox is a six speed gear that has some other important components inside it which made it run, like: (1) Shafts. (Lay Shaft, the Input shaft, Output shaft, Gear Selector rod).

(2) Dog Clutch. (3) Gear selector Forks. (4) The straight cut gear

(1) SHAFTS. A rear-wheel-drive transmission has three shafts: an input shaft, a countershaft and an output shaft. The countershaft is sometimes also called a lay shaft. The input and output shaft lie along the same line, and may be combined into a single shaft within the transmission. This single shaft is called a main shaft. The input and output ends of this combined shaft rotate independently, at different speeds, which is possible because one piece slides into a hollow bore in the other piece, where it is supported by a needle-roller bearing. Sometimes the word main shaft refers to just the input shaft or just the output shaft, rather than these two shafts together.

(2) Dog Clutch. The output shaft with a gear is achieved by means of a dog clutch selector. The dog clutch is a sliding selector mechanism which splined to the output shaft, meaning that its hub has splines that fit into splines on the shaft, forcing that shaft to rotate with it.

(3) Gear Selector Fork. What the gear selector does is to lock one of the freely spinning gears to the output shaft that runs through its hub via the dog clutch that is spinning with the output shaft. The shaft then spins together with that gear.

(4) Straight Cut Gears. The gears used for this form of gearbox are the straight cut gear which help their teeth in meshing together as fast as possible, they are very loud when in operation but produce a very low lost in power and moves very fast so as to produce more torque when they come in position with each other. The production is another very important thing to look at. Gear production is referred to as the process of making/manufacturing gears into their different forms, before this could be accomplished they will have to undergo different processes with the application of machines in order to get there various final dimensions shapes and surface finishing’s. The Processes of production are as follows; (1) The Casting (2) the Forging (3) Extrusion (4) Powder Metallurgy and (5) Blanking.

Before gears can be produced the materials to be used are also important to be put into consideration. Like;

(1) The materials must have a low coefficient of friction. (2) The material must have high endurance strength to withstand dynamic loads.

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(3) The material must have high tensile strength to prevent failure against static loads.

(4) The material should also have good manufacturability.

So once all this has been considered then the processes can start For example,

(1) The forming (2) The milling (3) broaching and also (4) Gear hobbing. All these processes are done with the use of machineries that also give it their various teeth shapes that mesh into one another during engagement.

(1) The Forming. The forming process is a way of using two machines like the milling and broaching in forming the specified type of teeth needed for the gears either helical or a straight cut.

(2) The milling.  In the process of milling, the cutter is needed to travels axially along the length of the gear tooth at the appropriate depth to produce the gear tooth.

(3) The broaching. This method is also used to produce gear teeth and this is applicable to internal teeth, broaching gives a good dimensional accuracy, they are meant for highly quantity production, broaching is usually used when precision machine is required, majorly for odd shapes. It is regarded as an unusual machine process this is due to the feed that is built on the tool. Broaching has some teeth fitted into it which helps in determining the amount of the material to be removed and also the size of the chip, the broach itself can move to the work piece and vice versa due to the features that are built on the broach so there is no need for skilled labor or complex motion before it could be used. The surface of the machine could be circular and non-circular shapes. The disadvantage of this is that it is an expensive process.

(4) The Gear hobbing. In the case of hobbing the gears are generated by a series of cuts, the motion in the case of hobbing is a rotary motion in which the gear hob rotates rounds so as to get the teeth type as they mesh into one another.

The two important steel materials used in gear production are the; (1) Cast Iron. (2) Non Ferrous materials.

Cast iron is one of the oldest ferrous metals that is normally used in construction works, It majorly comprises of Iron (Fe), Carbon (C) and silicon (Si) but could comprise of other forms too like phosphorous. It is made up of amount of carbon content. Cast iron are very hard, brittle and non-malleable that is, cannot be beaten to sheets. Cast Iron are very good for high compression works.

Non Ferrous Metals are; Aluminium. Copper. Brass. Lead. Zinc and Electric Cables.

But the cast iron is also a form of steel used in the production of gears, this is because of their high tensile in strength and cost is very low. The steels are examples of alloys and carbon, steels are of various grades depending on the purpose to be used for as at today steels are used in the production of so many things like; Tools, Ships, Automobile Machines, Weapons and many more.

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ADVANTAGES OF GEARS.(1) With the help of gears drivers can move around form a gear to another.(2) Gears also helps the car in taken off from a static position.

DISADVANTAGES OF GEARS.(1) Straight cut gears produce a very loud noise.

(2) Gears can only work on the same gears with the same type of teeth, otherwise the teeth will not mesh into one another.

CONCLUSION.

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A sequential manual gearbox is a non-traditional type of manual transmission used on most high-performance cars for auto racing. The gearbox is a five speed gear that has some other important component inside it which made it run, like: (1) Shaft. (The Lay shaft, the Input shaft, the Output shaft and the Gear Selector rod). (2) Dog Clutch. (3) Gear selector Fork. This single shaft is called a main shaft. The input and output ends of this combined shaft rotate independently, at different speeds, which is possible because one piece slides into a hollow bore in the other piece, where it is supported by a needle-roller bearing. The straight cut gear which help their teeth in meshing together as fast as possible, they are very lousy but produce a very low lost in power and moves very fast so as to produce more torque when they come in position with each other.

APPENDICES.

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REFFERENCES.

Margot Gayle, David. Look, John G. Waite. Metals in America’s Historical Buildings. Washington, Dc: National Park Service, 1992. (USGPO 1992-332-360)

L. Williams Zahner. Architect Metals: A Guide to Selection, Specification, and Performance. New York City: John Wiley & Sons, 1995.

Josh Smith. Chassis. In: Josh Smith (eds.) Smith’s Fundamentals of Motorsport Engineering. 6th ed. Cheltenham, England: Nelson Thorne’s Ltd; 2013. Page (50 - 59).

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