International Journal of Engineering and Advanced Technology (IJEAT) ISSN: 2249 – 8958 (Online), Volume-9 Issue-4, April 2020 487 Retrieval Number: D7015049420/2020©BEIESP DOI: 10.35940/ijeat.D7015.049420 Journal Website: www.ijeat.org Published By: Blue Eyes Intelligence Engineering & Sciences Publication © Copyright: All rights reserved. Design of an ATV Gear Box Mohit Pillai, Naman Sharma, Vinit Bhandari, Ram Bansal Abstract: The main objective of the project was to design and fabricate a drive train for an intercollegiate competition called BAJA SAE. The motive to get into this project was to learn more about an All-Terrain Vehicle (ATV), studying about different parameter which would affect the drive train of the vehicle. All the possible options were considered while making the drive train. After discussions alternative options were taken neglected and the main option was chosen. It was decided that the transmission would be automatic, consist of a continuously variable transmission (CVT) couples with a two staged gearbox which is then couples with the half shaft. The whole system was tested thoroughly and it performed well. Keywords: ATV, CVT, spur gear, compound gear train, gear box. I. INTRODUCTION In the ATV drive train consist of Engine which is coupled with a CVT, CVT is coupled with the compound gear train which is then connected to half shaft. The engine used in drive train is of Briggs and Stratton, the engine is of 305cc, producing 10 hp and 19.2 NM of torque at 2800 RPM. There are various transmission options like manual, semi- automatic, automatic. The problem with manual transmission is that you have to shift gears, that creates a problem for the drives as it would quite difficult for a driver to shift in an uneven, rough terrain. Same is the case with semi-automatic. While in automatic transmission there is no need of shifting as everything is automatic. In this case a CVT is selected for automatic transmission. CVT provides a maximum ratio of 3.9:1 in under drive condition and 0.75:1 in overdrive condition. The torque produced by the engine and CVT is not enough to run the vehicle, so the remaining torque is provided by gearbox which a compound gear train consist of two stage reduction. II. OBJECTIVES Design a system that would make the torque required to move the vehicle and to design a gearbox that would maintain the required centre distance between input shaft which is connected to secondary CVT and the output shaft which is connected to the half shaft. The system has to be cost effective, light weight and efficient.Vehicle) with an The gearbox is designed for an ATV (All-Terrain Vehicle) with an engine of following spec. Revised Manuscript Received on March 16, 2020. * Correspondence Author Mohit Pillai*, Mechanical Engineering Department, Medi-Caps University, Indore, India, mohitpillai0298@gmail.com Naman Sharma, Mechanical Engineering Department, Medi-Caps University, Indore, India,namansharma415@gmail.com Vinit Bhandari, Mechanical Engineering Department, Medi-Caps University, Indore, India, vinitbhandai13@gmail.com Ram Bansal, Mechanical Engineering Department, Medi-Caps University, Indore, India, ram.bansal@medicaps.ac.in © The Authors. Published by Blue Eyes Intelligence Engineering and Sciences Publication (BEIESP). This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/ )  Capacity: 305cc  Maximum Torque: 19Nm @2800 rpm  Maximum power: 10Hp @3800 rpm III. SIGNIFICANCE The findings of this study will redound for automotive society considering that power to weight ratio is consequential for an ATV. A final drive gear box provides a fixed reduction to overcome the lack of torque produced by the CVT in pair with the specified engine. This final drive gearbox is designed to produce maximum torque with high efficiency. IV. DESIGN SPECIFICATION Table No. I - Gear Specification Specificatio n Input pinio n Intermediat e pinion Intermediat e gear Outpu t gear Number of Teeth 23 53 19 73 Module 2 2 2.5 2.5 Pressure angle 20 o 20 o 20 o 20 o Face width 12 12 15 15 Pitch Circle Diameter 46 106 47.5 182.5 a) Input shaft Input pinion is integrated with the input shaft of the gearbox. Input shaft couples CVT to the gearbox through the splines. b) Intermediate shaft Intermediate shaft has intermediate pinion integrated on it and intermediate gear is mounted through a key way. c) Output shaft Output gear is mounted on to the output shaft through a key way. Half shafts are coupled with the help of splines. d) Oil seals Oil seals are used to prevent leakage of oil and it also oil and to also prevent dust particles from entering the gear box casing. e) Bearings Bearings used in gearbox are tapper roller bearing. V. DESIGN PROCEDURE