DESIGN AND ANALYSIS OF A TWO STAGE REDUCTION GEARBOX

An All-Terrain Vehicle is an Off-Road vehicle that has the ability to drive on any terrain without any difficulty. BAJA vehicles are the most famous Off Road Vehicles in India. However, due to the extreme loads caused by the gravel tracks and the constraints to reduce the weight, one major component is susceptible to failure Reduction Gearbox. The Power Train assembly is so complicated that it occupies a lot of space in the vehicle hence increasing the overall weight. The objective of this project is to design a gearbox that is compact, lightweight and has extended life. Major fields covered are Material selection, Machine Engineering Design of Gears, Shafts, Gearbox Casing, bearing selection, Vibrations caused due to the Engine. These analytical designs have been validated through the help of CAD and FEA software like Solid Works and ANSYS. Various Analysis like Structural, repeated loads and Computational Fluid Dynamics (CFD) have been performed to study the behavior of components and oil flow during operations. The design is also finalized with the fits required for assembly and the final product is expected to be efficient, lightweight, compact and long lasting than the other Gearboxes being used today.