Eureka! Institutional Repository

In this thesis, a mechanical gearbox, which is used for the well-known Volkswagen model "Polo MK4" codenamed "02T", is studied, designed and finally 3D printed. This specific gearbox consists of five (5) speeds and one (1) reverse manual transmission. It comprises of two (2) axes, the primary axis and the secondary one as well as one other for the reverse. With a specified transmission ratio, the gearbox is connected to the differential, which gives the power/drive to the wheels. In the first chapters, general data and information relating to the gearbox, and more specifically to the "02T" mechanical gearbox, are mentioned. In addition, the gears are studied more closely in terms of type, special characteristics and geometrical size. Furthermore, the study includes the complete calculation of the cogwheel size and the surface and fracture test results. In the fourth chapter, the process of designing the gearbox is presented and printed through a 3D printer, using snapshots from the 3D Solidworks programme. Finally, the conclusions and observations from all the stages of the design of a gearbox are recorded.