Analysis of gearbox components using ANSYS and Adams
CAE Project | BEng Mechanical Engineering
This project involved the concept development and structural analysis of a vehicle transmission system, focusing on the transfer of torque from a gearbox output shaft to a differential axle.
The study compares two primary drive methods:
- Sprocket and Chain System (Kinematic & Stress Analysis)
- Pulley and Belt System (Final Design Choice)
Used ADAMS to obtain real-time data on:
- Torque Ratios: Achieved a ratio of 4.25 for optimized acceleration.
- Angular Velocities: Calculated flow of torque through the chain links and bushings.
- Force Vectors: Identified highest stress points on the chain pins during motion.
Conducted FEA on the pulley components to ensure structural integrity:
- Total Deformation: Analyzed deformation nodes furthest from mounting points.
- Equivalent Stress (von-Mises): Verified that stresses remained within material limits for the pulley coupler and front pulley.
- Front/Rear Pulleys: Designed to ISO 5294 specifications.
- Trapezoidal Toothed Belt: Selected for slip reduction and efficiency.
- Mounting: M10 Hexagon Head Bolts and locational interference fits.
The complete engineering methodology, including design justifications and simulation results, can be found here:
- Final CAE Project Report (PDF) – Detailed ANSYS deformation results and ADAMS modeling.
- Transmission System Presentation (PDF) – Concept development, stress flowcharts, and system reviews.
Core Skills: Finite Element Analysis (FEA), Multi-Body Dynamics, ISO Standards, Component Justification.