OPTIMIZATION OF OIL QUANTITY IN MANUAL TRANSMISSION AND REDUCING CHURNING LOSS

Gearbox efficiency losses are contributed by Oil seal rubbing, Synchro friction rubbing, Gear losses, bearing preload friction, windage losses, churning losses etc. Here in this experiment we have focused on quantifying and reducing the churning losses as well as verifying the lubrication requirements satisfactorily in all terrains and conditions. The paper establishes the effective way for evaluating same with over 80 trials conducted for conclusive proof. Gearboxes must work efficiently to get the job done properly and lubrication is vital to this efficiency. Lubricating oil is like the circulation system of a gearbox. If the oil levels fall too low, the gearbox will likely fail. Gearbox failure can lead to expensive repairs that could be prevented. Besides added costs due to replacement or repair, costs associated with a loss of production could be significant. These issues are why it is important to understand the consequences of having low lubricant levels. Similarly, higher oil level creates higher churning losses, heating of the Gear oil and oxidation, reduction in efficiency, oil leaks. Understanding the functions of gearbox lubricating oil can help you choose the right quantity of prevent gearbox failures. The aim of the paper is to explore the novel method to find the accurate level of oil required to lubricate the Gearbox properly without failure and to reduce from the current level which is deemed high. The churning loss due to higher oil quantity will also be reduced in course of the trial and finally contributing to increased efficiency of Gearbox. The various methods test the input shaft bearing oil flow, rear bearing oil flow and checks whether the oil reaches the spigot bearing. The failures like fretting due to lubrication is addressed. The attitude of the GB during operation at various terrains are being checked via 80 different trails and the final optimized level achieved.