Modeling and structural analysis of two stage gear box with different materials

An all-terrain car is an off-road vehicle which can travel without any problems on any terrain. These vehicles support some kind of extreme loads while off-road travel. All-terrain cars are equipped with wide tyres with grooves for greater stability on slippery terrain and good ground clearance to prevent obstacles. These cars are designed to also be stronger and longer lasting than commercial vehicles. In Deserts, these cars are widely used. Design of gears, shafts, gearbox cassettes, bearing collection, engine vibration and engine design. The gearbox is coupled to a Continuously-Variable Transmission which is powered by a 7.5KW-four-stroke gasoline engine. The first stage includes parameters calculations to obtain dimensions of the gearbox and its components. The second stage involves design modeling of the components in CATIA V5R21. In next stage, Finite-Element analysis is performed to validate the design in ANSYS 14.5. The final stage involves testing of the gearbox on diverse and harsh terrains. The volume of the all gears and shafts calculated with the classical method is 99.3788 cu.in, while the optimal design solution offers a smaller volume, equal to 67.069 cu.in. i.e. a 32.503% reduction.