MINISTRY OF EDUCATION AND TRAINING

HO CHI MINH CITY UNIVERSITY OF

TECHNOLOGY AND EDUCATION

FACULTY OF INTERNATIONAL EDUCATION

FINAL PROJECT
DESIGN AND CALCULATION OF MANUAL
TRANSMISSION GEARBOX OF HYUNDAI GRAND I10
2018 1.0 MT
LECTURE: DR. NGUYEN MANH CUONG
STUDENT: NGUYEN DINH KHOI
STUDENT ID: 21145588
STUDENT: LE TRUNG KIEN
STUDENT ID: 21145589
STUDENT: DAO CHI TAM
STUDENT ID: 21145611
STUDENT: PHAM NGUYEN THAI BAO
STUDENT ID: 22145009

Ho Chi Minh City, November 2024

 TABLE OF CONTENTS
OVERVIEW..........................................................................................................
1. Reason for choosing the topic...........................................................................
2. Research objectives...........................................................................................
3. Research content................................................................................................
4. Method of implementation................................................................................
CONTENTS...........................................................................................................1
Chapter 1: INTRODUCTION..............................................................................1
1.1. History of formation and development of Hyundai..................................1
1.2. Hyundai Grand i10 2018 1.0 MT model.....................................................18
1.3. Manual Transmission of Hyundai Grand i10 2018 1.0 MT......................20
Chapter 2: THEORETICAL BASIS...................................................................26
2.1. Introduction to Hyundai i10 MT gearbox..................................................26
2.2. Structure of Hyundai i10 MT gearbox.......................................................26
2.3. Working principle of Hyundai i10 MT gearbox........................................29
2.4. Specifications.................................................................................................30
2.5. Power transmission diagram.......................................................................30
2.6. Advantages and disadvantages of Hyundai i10 MT transmission...........32
Chapter 3: GEARBOX DESIGN AND CALCULATION................................34
3.1. Preliminary parameters of Grand i10 gearbox.........................................34
3.2. Gear parameters selecting and calculating................................................36
3.3. Gear durability calculation..........................................................................39
3.4. Shaft design and calculation........................................................................44
3.5. Bearings design and durability calculation................................................44
INFERENCE..........................................................................................................48
REFERENCES......................................................................................................49
 OVERVIEW
1. Rationale for Choosing the Topic.
- Importance of Transmission Systems in Automobiles: The transmission
system is a critical component that determines the transfer of power from the
engine to the wheels, impacting vehicle speed, torque, and acceleration. Manual
transmissions (MT) are preferred in certain segments due to their ability to provide
better control and efficiency in specific driving conditions, particularly in hilly
terrains or when rapid acceleration is required.
- Trends in Automotive Technology: The automotive industry is undergoing a
rapid transformation with advancements in automation technology; however, the
demand for manual transmissions remains significant, especially in emerging
markets. Researching and enhancing manual transmission systems can improve
performance and meet consumer needs effectively.
- Hyundai Grand i10 2018: This model is a popular urban vehicle in Vietnam,
known for its modern design and superior features. Investigating the transmission
system of this model not only aids in understanding automotive technology but
also allows for proposing enhancements to improve durability and performance.
2. Research Subject
- Manual Transmission (MT): The study will focus on the structure, operating
principles, design, and calculations related to the manual transmission system of
the Hyundai Grand i10 2018. This includes an examination of the control
mechanisms and the impact of the transmission on overall vehicle performance.
- Components of the Transmission System: A detailed analysis of individual
components such as gears, shafts, clutches, and control mechanisms to understand
their roles and functions within the powertrain system.
3. Research Content
- Structure and Operating Principles: Investigate how the design of the
transmission affects performance, including the arrangement of gears and how
torque is transmitted through the components.
 - Calculation of Technical Parameters: Perform calculations to determine gear
ratios, optimal torque, resistance forces, and other essential parameters to ensure
the transmission operates efficiently. These calculations will be based on the
engine characteristics and operational requirements.
- Transmission Design: Utilize CAD (Computer-Aided Design) software to
create a 3D model of the transmission system, develop detailed technical drawings,
and analyze the structural integrity of each component. This process helps identify
and rectify weaknesses in the design before actual production.
- Comparison with Other Transmission Types: Research and analyze the
advantages and disadvantages of manual transmissions compared to automatic
transmissions (AT) and continuously variable transmissions (CVT). This will
provide insights into the position of manual transmissions within the contemporary
automotive market.
4. Methodology
- Theoretical Analysis: Conduct a literature review of existing materials and
resources related to transmission design and calculations. This will include
studying academic papers, technical books, and relevant engineering standards to
gather comprehensive knowledge.
- Simulation and CAD Design: Employ CAD software to create a 3D model
of the transmission. Simulate the operation of the transmission under various
conditions to evaluate its performance.
- Technical Calculations: Apply physical and mechanical formulas to compute
technical parameters such as gear ratios, resistance forces, and torque. This will
involve using computational software for calculations and technical analysis.
- Experimental Validation: If feasible, conduct experiments on a vehicle or
model to assess the transmission's performance in real-world conditions. Analyze
the data collected to draw conclusions and suggest improvements.

CONTENTS
 Chapter 1: INTRODUCTION

1.1. History of formation and development of Hyundai.

1.1.1. History of Formation and Development of Hyundai.
Hyundai is one of the largest and most renowned conglomerates in South
Korea, founded in 1947 by Chung Ju-Yung. From a small construction company,
Hyundai has evolved into a leading multinational corporation with a presence in
various industries, including automotive manufacturing, shipbuilding, electronics,
finance, and more. Here’s a detailed overview of Hyundai's formation and
development.
Formation Phase (1947-1960)
- Establishment of Hyundai Engineering and Construction Co. (1947): In
1947, Hyundai Engineering and Construction Co. was founded by Chung Ju-Yung,
a man who came from a poor farming background in Korea. Growing up in a
challenging environment, Chung experienced various occupations before
establishing the company. His diverse work experiences, ranging from farming to
trading, equipped him with the skills and insights needed to navigate the business
landscape. With a strong passion and determination, he founded Hyundai with the
goal of contributing to the reconstruction of South Korea after World War II. He
recognized that Korea needed a robust infrastructure to recover and develop
economically. In the early days, Hyundai faced numerous challenges, including
financial difficulties. However, with his resilience and leadership abilities, Chung
gradually built a reputable company.
- Role During the Korean War and Reconstruction (1950-1953): During the
Korean War from 1950 to 1953, Hyundai became one of the most important
companies in providing construction services and repairing infrastructure. The war
caused significant damage to Korea's infrastructure, and Hyundai's mission was
daunting. The company participated in many critical construction projects,
including:
 Building Roads: To meet the needs for transportation and logistics during
the war, Hyundai constructed and repaired hundreds of kilometers of roads. These
roads not only facilitated connectivity between different regions but also enabled
economic activities and provided safer passage for civilians.
 Constructing Bridges: The bridges built by Hyundai were crucial for
maintaining secure transport routes, especially during wartime. The construction
of these bridges played a vital role in connecting rural areas with urban centers
and was essential for transporting goods and food, which were critically needed
during the conflict.
 Other Construction Projects: In addition to transportation infrastructure,
Hyundai was involved in constructing hospitals, schools, and other public
facilities, improving the quality of life for Koreans during this challenging time.
The company's presence in construction not only aided economic recovery but
also created millions of jobs, contributing to social stability in the post-war
period.
- Rapid Growth: Thanks to its efforts and successes in executing significant
construction projects, Hyundai quickly established itself as a leading player in the
South Korean construction industry. The company experienced a remarkable
increase in revenue, which facilitated its robust growth in the years that followed.
Hyundai's active involvement in rebuilding the nation after the war laid a solid
foundation for its multi-industry expansion in subsequent decades. In a relatively
short time, Hyundai emerged as one of the top construction companies in Korea,
and this success opened up numerous new opportunities for diversification into
other sectors, such as automobile manufacturing, shipbuilding, and electronics.
With strategic vision and innovative capacity, Hyundai gradually evolved into a
leading multinational conglomerate, making significant contributions to Korea's
economic development. In summary, the formation and development phase of
Hyundai from 1947 to the 1960s not only marked the beginning of one of Korea's
largest conglomerates but also showcased Chung Ju-Yung's vision and
determination to rebuild the country after the devastation of war. Through this
effort, Hyundai contributed significantly to reconstructing infrastructure and
promoting the economic and social advancement of Korea during its most
challenging times.
Expansion into the Automotive Sector (1960s-1970s)
- 1967: Formation of Hyundai Motor Company (HMC): Chung Ju-Yung
established Hyundai Motor Company (HMC), marking a significant transition
from construction to automobile manufacturing. The establishment of HMC not
only reflected his visionary outlook but also opened a new chapter for South
Korea's automotive industry. In the early stages, Hyundai partnered with Ford
Motor Company to assemble the Ford Cortina, laying the foundation for the
domestic automotive sector. This collaboration not only allowed Hyundai to gain
valuable experience in car manufacturing but also promoted the development of
production techniques and standards, helping the company adopt advanced
technologies from one of the world's leading automakers. The formation of HMC
also mirrored South Korea's economic transformation following the Korean War.
The South Korean government encouraged investment in industrial sectors to spur
economic development, and Hyundai's entry into the automotive market was a part
of this broader plan. HMC not only created job opportunities but also stimulated
growth in related industries, from parts suppliers to logistics and after-sales
services.
- 1975: Launch of the Hyundai Pony – Korea's First Car: Hyundai developed
and launched the Hyundai Pony, the first car produced in South Korea. Designed
by the renowned Italian engineer Giorgetto Giugiaro, who is famous for his
impressive automotive designs, the Pony utilized engines sourced from Mitsubishi
Motors. The vehicle boasted an attractive design and provided high performance
and reliability, making it well-suited to meet domestic market needs. The Hyundai
Pony was priced affordably, making it an appealing choice for South Korean
consumers. The launch of this model marked a significant milestone in the history
of South Korean automotive manufacturing and showcased Hyundai's ability to
produce high-quality vehicles domestically. The Pony quickly dominated the
market, experiencing rapid sales growth and receiving enthusiastic acceptance
from consumers. This success not only solidified Hyundai's position in the
automotive sector but also helped to establish consumer trust in domestic products.

- Late 1970s: Beginning of International Exports: Following the success of

the Pony in the domestic market, Hyundai began expanding internationally by
exporting vehicles to markets such as Ecuador, Belgium, and Canada. The
Canadian market was particularly significant, as it became one of Hyundai's
earliest large foreign markets. Hyundai's entry into international markets not only
boosted the company's revenue but also provided opportunities to build a global
brand. Each new market that Hyundai entered came with its own unique challenges
and opportunities. To succeed in foreign markets, Hyundai adapted its products to
meet the preferences and demands of local consumers. The flexibility in business
strategy and the ability to adapt to changing market environments helped Hyundai
not only survive but thrive during this period.
Global Expansion and Diversification (1980s-1990s)
- 1986: Entry into the U.S. Market: A pivotal moment in Hyundai's
international expansion strategy occurred in 1986 when the company entered the
U.S. market with the Hyundai Excel. Known for its affordability, the Excel sold
over 100,000 units in its first year in the U.S., establishing Hyundai as a
competitive player in a highly competitive market.
- 1990s: Diversification of Operations: In the 1990s, Hyundai continued to
diversify into new industries, including shipbuilding, heavy machinery
manufacturing, electronics, and financial services. Hyundai Heavy Industries
(established in 1972) became the largest shipbuilding company in the world, while
Hyundai also expanded into the semiconductor industry, playing a vital role in
developing South Korea's technology sector.
- Quality Issues and Brand Image: Despite early successes, Hyundai faced
significant product quality issues, particularly in the U.S. market during the 1990s.
Hyundai vehicles were often perceived as unreliable and of poor quality,
negatively impacting the brand image. To address this, Hyundai heavily invested
in research and development (R&D) to improve product quality.
 Modernization and Focus on Premium Segments (2000s-2020s)

- 1998: Acquisition of Kia Motors: After the Asian financial crisis in the late
1990s, Hyundai Motor acquired 51% of Kia Motors, another struggling South
Korean automaker. This acquisition created one of the largest automotive groups in
the world and enabled Hyundai to expand production capacity and market reach.
- 2004: Launch of the Hyundai Sonata and New Design Strategy: In 2004,
Hyundai introduced a completely new version of the Sonata, one of its most
successful models globally. This was also the time when Hyundai began
implementing a new design strategy, based on the philosophy of “fluidic
sculpture,” aiming to create a more premium brand image.
- 2009: Introduction of Genesis and the Luxury Segment: In 2009, Hyundai
launched the luxury sedan Genesis, designed to compete with premium brands like
BMW and Mercedes-Benz. This marked a significant milestone in Hyundai's entry
into the luxury vehicle segment. By 2015, Genesis was established as an
independent luxury brand of Hyundai.
- 2010s: Focus on Quality, Warranty, and R&D: In the 2010s, Hyundai
significantly improved its brand image by concentrating on product quality,
introducing a 10-year warranty in key markets such as the U.S., and heavily
investing in R&D. The company also developed fuel-efficient and hybrid vehicles
to align with global sustainability trends.
- Electric Vehicle and Hydrogen Technology Development: Hyundai emerged
as a pioneer in developing environmentally friendly vehicle technologies,
launching electric models such as the Hyundai Kona EV and hydrogen fuel cell
vehicles like the Hyundai Nexo. The company has made substantial investments in
both electric battery technology and hydrogen fuel cell technology, with ambitions
to lead the sustainable transportation revolution.
1.1.2. Hyundai's Future Vision in the Automotive Industry.

Hyundai Motor Company is laying out a bold and comprehensive strategy for
the future, envisioning a transformed automotive landscape dominated by electric
vehicles (EVs), autonomous driving, and advanced smart technology. With a clear
long-term vision, Hyundai aims to lead the industry in innovation, sustainability,
and technological development. Here’s an in-depth look at Hyundai's future vision
and key areas of focus:
1. Carbon Neutrality by 2040: One of Hyundai’s most ambitious goals is to
achieve carbon neutrality by 2040. This target aligns with global efforts to reduce
greenhouse gas emissions and address the growing environmental concerns
surrounding climate change. Hyundai plans to phase out vehicles powered by
traditional internal combustion engines (ICEs) in key markets and shift towards
electric vehicles (EVs) and hydrogen fuel cell vehicles (FCEVs). The company’s
commitment not only meets evolving environmental regulations but also enhances
its social responsibility to combat climate change, ensuring Hyundai plays a
pivotal role in protecting the planet for future generations.
2. Strong Focus on Electric Vehicle Development: To achieve its carbon
neutrality goals, Hyundai is making a strong push in electric vehicle development,
accelerating the launch of new models and expanding its EV lineup. A key
example of this is the Ioniq line, which showcases Hyundai’s innovation and
dedication to the EV market.
- Ioniq 5: Hyundai’s flagship EV, the Ioniq 5, has already gained widespread
praise for its futuristic design, advanced technology, and long-range capabilities. It
represents a major leap forward in Hyundai’s EV strategy and positions the
company as a strong competitor in the growing electric vehicle sector.
- Upcoming Ioniq Models: Hyundai is preparing to introduce the Ioniq 6 and
Ioniq 7, which will further expand the company’s electric vehicle portfolio. These
models aim to target various segments of the market, offering a wide range of
options for consumers and ensuring Hyundai’s competitiveness with major players
like Tesla, Volkswagen, and other automotive giants pushing aggressively into the
EV space.
3. Investment in Hydrogen Fuel Cell Vehicles (FCEVs): In addition to EVs,
Hyundai is heavily investing in hydrogen fuel cell technology, viewing hydrogen
as a critical part of the clean energy future. The Hyundai Nexo, one of the world’s
first mass-produced hydrogen fuel cell SUVs, exemplifies the company’s early
leadership in this field. Hyundai aims to expand its lineup of FCEVs and leverage
hydrogen’s potential as a sustainable energy source, offering a viable alternative to
battery electric vehicles (BEVs), especially for long-range and heavy-duty
applications. The company envisions hydrogen as a crucial energy solution for
commercial vehicles, public transportation, and other sectors that demand longer
driving ranges and faster refueling.

4. Autonomous Vehicles and Smart Mobility Technology: Hyundai is

positioning itself as a frontrunner in the development of autonomous vehicles
(AVs) and smart mobility solutions. The company's acquisition of Boston
Dynamics in 2020 signaled its commitment to robotics and automation, areas
closely related to the future of autonomous driving.
- Partnerships and Innovations: Hyundai has also partnered with Aptiv, a
leader in self-driving technology, to form Motional, a joint venture focused on
creating fully autonomous vehicles. This partnership is expected to accelerate
Hyundai’s entry into the self-driving vehicle market, with a clear goal of offering
level-4 autonomous vehicles (capable of operating without human intervention) in
the coming years.
- Smart Mobility Solutions: Beyond autonomous vehicles, Hyundai is
developing smart mobility solutions that integrate connected vehicle technology,
artificial intelligence, and data analytics to create safer, more efficient
transportation ecosystems. These advancements aim to reduce traffic congestion,
lower emissions, and improve urban mobility through innovative solutions like
smart fleets and shared autonomous services.
5. Global Expansion and Advanced Manufacturing Technologies: To support
its ambitious goals, Hyundai is focusing on expanding its production capabilities
and modernizing its global manufacturing infrastructure.
- Strategic Global Manufacturing: Hyundai is investing in new and advanced
manufacturing facilities in key regions such as the U.S., India, and Europe. These
facilities are designed to meet the growing demand for electric and smart vehicles
while enhancing the company’s global production network.
- Automation and Efficiency: Hyundai is embracing automation and other
advanced manufacturing technologies to improve efficiency, reduce production
costs, and optimize its operations. This approach will allow Hyundai to remain
competitive and agile in a rapidly evolving industry. The company’s goal is to
become one of the most efficient automobile manufacturers globally, maximizing
profitability and enabling sustainable growth.
6. Integration of Artificial Intelligence (AI) and Big Data: As part of its
forward-looking strategy, Hyundai is deeply investing in the integration of
artificial intelligence (AI) and big data across its business, from product
development to manufacturing and customer experiences. AI is expected to play a
critical role in enhancing the capabilities of future vehicles, particularly in areas
like autonomous driving, predictive maintenance, and intelligent in-car systems.
- Autonomous Driving: AI will help optimize Hyundai's autonomous driving
technology, enabling vehicles to process complex data in real-time for safer and
more efficient driving experiences.
- Smart Features: AI is also being applied to create personalized in-car
experiences, enhancing convenience, safety, and entertainment for users. Big data
analytics will provide insights into customer preferences, driving patterns, and
vehicle performance, which will help Hyundai continually improve its products
and services.
 1.1.3. Current Position of Hyundai in the Automotive Industry.

As of now, Hyundai Motor Group, which includes both Hyundai and Kia, has
established itself as one of the largest automotive manufacturers globally, ranking
third in the world in vehicle sales, behind only Toyota and Volkswagen. With a
presence in over 190 countries and millions of vehicles sold annually, Hyundai has
emerged as a formidable competitor in the international market. This success is
driven by several key factors:
- Global Production Scale: Hyundai has built a vast network of manufacturing
and assembly plants in various countries, including South Korea, the U.S., India,
China, the Czech Republic, Brazil, and more. This presence not only enables
Hyundai to connect more closely with international consumers but also optimizes
production processes, reducing costs and transportation time.
- Diverse and Continuously Improving Product Line; Hyundai stands out with
its diverse product range, from economy cars like the Hyundai Elantra and
Hyundai Sonata to SUVs like the Hyundai Tucson and Hyundai Santa Fe. The
company continuously improves its designs and incorporates modern technologies
to meet the rising demands of consumers. Notably, the establishment of the
Genesis brand has allowed Hyundai to assert its presence in the luxury segment,
competing with established luxury brands such as BMW, Mercedes-Benz, and
Lexus.
- Leadership in Electric and Hydrogen Fuel Cell Vehicles; Hyundai has been
heavily investing in electric vehicle (EV) and hydrogen fuel cell vehicle (FCEV)
technologies, with notable models such as the Hyundai Kona EV, Hyundai Ioniq,
and Hyundai Nexo. These vehicles are pioneering efforts to reduce emissions and
promote sustainability within the automotive industry. The recent success of the
Hyundai Ioniq 5 has further solidified Hyundai's leading position in the electric
vehicle era.
- Reputation for Quality and Customer Service; Hyundai has made significant
investments in enhancing product quality and after-sales service, highlighted by its
10-year/100,000-mile warranty program in the U.S.—one of the best warranty
programs in the industry. This commitment has helped the company regain
consumer trust following challenges related to quality in its early years of entering
the international market.
- -Strong Presence in the U.S. Market; The U.S. is one of the largest and most
competitive automotive markets in the world. Through models like the Hyundai
Sonata, Hyundai Tucson, and its electric offerings, Hyundai has built a solid
position in this market. In 2023, Hyundai continued to grow its market share in the
U.S., particularly in the electric vehicle segment, thanks to the success of the Ioniq
5 and Ioniq 6.
- Enhancements and Expansion of the Genesis Luxury Segment; Genesis,
Hyundai's luxury brand, has achieved significant milestones, especially in
premium markets like the U.S. and Europe. Models such as the Genesis G70, G80,
and GV80 have garnered prestigious awards for quality and design, allowing the
Genesis brand to compete directly with top names in the luxury segment.
-

1.1.4. Hyundai's Position in Vietnam.

 Hyundai Motor has established itself as a major player in Vietnam’s
automotive industry, strengthening its market presence through strategic
investments, localized production, and a diverse product lineup. The company’s
strong commitment to delivering quality vehicles and its proactive approach to
market trends like electric mobility have allowed it to maintain a competitive edge
in this rapidly growing market. Below is an in-depth analysis of Hyundai's position
and its strategies to sustain leadership in Vietnam.
1. Dominant Market Share and Competitive Edge; Hyundai Thành Công, the
official distributor of Hyundai vehicles in Vietnam, has consistently ranked as one
of the top automotive brands in terms of sales, reflecting the brand’s strong
foothold in the Vietnamese market. Hyundai regularly competes with other top
players like Toyota and Kia for the highest market share in the country.
 - Best-Selling Models: Models such as the Hyundai Accent, Grand i10, Santa
Fe, and Tucson are some of the most popular vehicles on Vietnamese roads. The
Accent and Grand i10, in particular, are widely favored for their affordability, fuel
efficiency, and compact size, making them ideal for urban commuters. These
models have frequently appeared among the top 10 best-selling cars in Vietnam.
- SUV Segment: In the SUV segment, the Hyundai Santa Fe and Tucson have
garnered significant attention for their sleek designs, spacious interiors, and
advanced features. The rising demand for SUVs in Vietnam, driven by growing
affluence and preference for family-friendly, multi-purpose vehicles, has played
into Hyundai's strengths. These models appeal to customers looking for luxury,
comfort, and practicality in one package.
Hyundai's diverse product range and its ability to cater to different customer
needs - whether for affordable compact cars or premium SUVs - have been key to
maintaining a strong competitive position in the market.
2. Comprehensive Product Line to Meet Diverse Consumer Needs; Hyundai
has developed a diverse portfolio of vehicles tailored to the preferences of
Vietnamese consumers. This approach enables the company to capture a wide
range of market segments, from budget-conscious buyers to those seeking luxury
and advanced technology.
- Compact and Budget-Friendly Cars: Hyundai's compact cars, like the
Accent and Grand i10, are highly popular due to their affordable pricing and
reliability. These vehicles are ideal for Vietnam’s dense urban areas, where small,
fuel-efficient cars are in high demand. Their modern designs, combined with
features such as touchscreen infotainment systems, rearview cameras, and
advanced safety features, make them appealing choices for a broad range of
customers.
- SUVs and Crossovers: The Santa Fe and Tucson SUVs have gained
significant market traction in Vietnam due to their premium styling, spacious
cabins, and robust performance. Hyundai has capitalized on the increasing
consumer demand for larger, family-oriented vehicles with advanced safety and
convenience features. The SUVs also feature Hyundai's latest technologies,
including multiple drive modes, intelligent safety systems, and high-tech
infotainment options.
- Luxury Models: Hyundai has also introduced more premium models in its
lineup, such as the Hyundai Palisade, to target the growing number of affluent
consumers in Vietnam. These high-end models offer sophisticated design, cutting-
edge technology, and exceptional performance, allowing Hyundai to compete in
the luxury segment against brands like Toyota, Mazda, and Ford.
3. Strategic Investment in Local Production; One of Hyundai’s key strategies
in Vietnam is its strong investment in local production, allowing it to offer
competitive pricing, maintain a stable supply, and meet local demand efficiently.
Hyundai's manufacturing plant in Ninh Bình province is a cornerstone of its
operations in Vietnam.
 - Ninh Bình Plant: Hyundai’s factory in Ninh Bình is part of the Hyundai
Thành Công Group and plays a critical role in producing vehicles for the domestic
market. This local production capability gives Hyundai a significant advantage
over its competitors, as it allows the company to reduce transportation costs,
shorten delivery times, and offer more competitive prices compared to fully
imported vehicles. The factory also aligns with Vietnam’s broader industrial policy
goals of promoting local production and reducing reliance on imports.
- Job Creation and Economic Impact: The Ninh Bình plant not only
strengthens Hyundai’s market presence but also contributes to Vietnam’s
economic development by creating thousands of jobs and fostering local skills in
automotive manufacturing. The plant's operations reflect Hyundai's long-term
commitment to Vietnam and its strategy of building sustainable growth through
localized production.
4. Focus on Quality and Customer Service; Hyundai has built a solid
reputation in Vietnam for offering vehicles that are not only stylish and
technologically advanced but also durable and reliable. The company has
continuously improved its customer service to meet the growing expectations of
Vietnamese consumers.
 - Comprehensive Warranty Programs: One of the key factors in Hyundai's
strong market position is its industry-leading warranty programs, which include
warranties of up to 5 years or 100,000 km. This extended warranty not only boosts
consumer confidence in Hyundai's vehicle quality but also helps the brand regain
trust after overcoming previous quality challenges in the global market.
- Customer Satisfaction: Hyundai also places a strong emphasis on after-sales
service, offering comprehensive service packages that cover routine maintenance,
repairs, and vehicle checks. Its network of authorized service centers across
Vietnam ensures that customers have easy access to professional vehicle care,
contributing to high levels of customer satisfaction.
5. Advancing in Electric Vehicles and Smart Technology; As the global
automotive industry shifts towards sustainable mobility, Hyundai is positioning
itself as a leader in electric vehicles (EVs) and smart vehicle technology. Hyundai
recognizes the growing demand for environmentally friendly transportation
solutions in Vietnam and the government's supportive policies toward clean
energy.
- Electric Vehicle Introduction: Hyundai is preparing to introduce its electric
vehicles to the Vietnamese market, including its Ioniq line, which has gained
global acclaim for its cutting-edge technology and sustainability. With increasing
environmental awareness and government incentives for clean energy vehicles,
Hyundai sees significant potential in the electric vehicle segment.
- Smart Mobility and Connectivity: Hyundai is also focusing on incorporating
smart technology into its vehicles, offering features like connectivity systems,
autonomous driving aids, and advanced safety technologies. These innovations
align with global automotive trends and reflect the growing consumer demand for
smarter, safer, and more convenient driving experiences.
6. Commitment to Corporate Social Responsibility (CSR); Hyundai is
actively involved in various corporate social responsibility (CSR) programs in
Vietnam, which have helped bolster its brand image and strengthen its connection
with local communities.
- Environmental Initiatives: Hyundai has taken part in environmental
protection activities, such as tree-planting campaigns and initiatives to reduce
carbon emissions, reflecting its global commitment to sustainability.
- Educational Support: The company has also supported education in Vietnam
through scholarships and funding for students, particularly in rural areas, aiming to
improve access to quality education and foster future generations of skilled
workers.
1.2. Hyundai Grand i10 2018 1.0 MT model.

Hyundai Grand i10 1.0 MT 2018: The Hyundai Grand i10 1.0 MT 2018 has
made a significant impact in the Vietnamese automobile market. This model stands
out for its affordable price, compact size, and modern features, making it an ideal
choice for city commuting and daily travel. Below is a detailed look at the Hyundai
Grand i10 1.0 MT 2018 in Vietnam.
Shape and Design:
 - Dimensions: The Grand i10 2018 measures 3,765 mm in length, 1,662 mm
in width, and 1,480 mm in height, with a wheelbase of 2,425 mm. This compact
size allows for easy maneuverability in busy urban areas.
- Exterior: The exterior design of the Grand i10 is modern and dynamic,
featuring a trapezoidal grille and sharp headlights. The LED daytime running lights
add to the vehicle's visibility, while the rounded lines create a friendly and
approachable look.
- Interior: The interior space of the Grand i10 is designed to be practical and
comfortable, with high-quality materials and refined details. The cabin is spacious
enough to accommodate five passengers, providing comfort for both the driver and
passengers.
Target Audience:
- Young Consumers: The Grand i10 primarily targets young customers,
including new professionals or small families looking for a compact, fuel-efficient
vehicle suitable for daily urban commuting.
- First-Time Drivers: With its friendly design and easy handling, the Grand
i10 is also an ideal choice for first-time drivers, thanks to its lightweight steering
and good visibility.
Notable Features:
- Touchscreen Display: The Grand i10 1.0 MT 2018 comes equipped with a
7-inch touchscreen that supports Bluetooth, USB, and AUX connectivity, making
it easy for drivers and passengers to connect their mobile devices.
- Automatic Climate Control: The automatic air conditioning system provides
optimal comfort within the cabin.
- Safety Systems: This model is equipped with numerous safety features,
including an ABS braking system, airbags for the driver and front passenger, and
emergency brake assistance.
 - Smart Key and Remote Control: The Grand i10 also features smart key
functionality and remote control for added convenience and safety.

Engine:
- Engine: It is powered by a 1.0L gasoline engine with three cylinders (Kappa
engine), delivering a maximum power output of around 66 horsepower at 5,500
RPM and a peak torque of approximately 94 Nm at 3,750 RPM.
- Transmission: The vehicle utilizes a 5-speed manual transmission,
enhancing fuel efficiency with an estimated consumption of around 5.4 liters per
100 km in mixed driving conditions.
1.3. Manual Transmission of Hyundai Grand i10 2018 1.0 MT.

The Hyundai Grand i10 2018 1.0 MT is equipped with a 5-speed manual
transmission, which provides drivers with an engaging driving experience and
greater control during their journeys. Below are the detailed aspects of this
transmission:

Technical Specifications

- Transmission Type: 5-speed manual transmission

- Configuration: 5 forward gears and 1 reverse gear
 - Gear Ratios: The carefully designed gear ratios optimize performance,
allowing drivers to effectively manage speed and power, making every ride more
enjoyable.

Driving Experience: The Hyundai Grand i10 1.0 MT 2018 offers a driving
experience that combines agility, control, and a touch of excitement, particularly
for those who enjoy the nuances of manual transmission. This model is designed to
provide drivers with a sense of engagement and responsiveness that is often
lacking in automatic vehicles, making it a popular choice among enthusiasts and
practical drivers alike.

- Driving Feel: A Connection to the Road: The Grand i10’s manual

transmission significantly enhances the overall driving experience by offering a
level of engagement that automatic transmissions simply cannot replicate. Drivers
have the freedom to select gears at their discretion, which not only makes the
driving experience more interactive but also fosters a deeper connection between
the driver and the vehicle.
 Enhanced Control: The ability to manually shift gears allows drivers to
adapt to different driving conditions effectively. Whether navigating through heavy
urban traffic, ascending hilly roads, or enjoying open stretches of highway, the
manual gearbox provides the flexibility to choose the most appropriate gear. This
control is particularly beneficial when maneuvering in stop-and-go traffic, where
quick downshifts can provide the needed acceleration to overtake slower vehicles
or merge into fast-moving lanes.
 Sporty Feel: The sportier nature of manual gear shifting appeals to driving
enthusiasts who appreciate the tactile feedback and direct engagement with their
vehicle. The mechanical connection of the clutch pedal and gear lever allows for a
more visceral driving experience, making each shift feel intentional and rewarding.
For those who relish the thrill of driving, the Grand i10 1.0 MT delivers an
enjoyable and satisfying ride.
 - Acceleration Capability: Smooth and Precise: One of the standout features
of the Grand i10 1.0 MT is its capability for smooth and precise acceleration,
thanks to the manual transmission. This aspect of the driving experience is
particularly appealing when dealing with varying traffic conditions or when a
quick burst of speed is required.
 Responsive Power Delivery: The manual transmission allows drivers to
control the power delivery of the 1.0-liter engine more effectively. By selecting
lower gears when needed, drivers can achieve quicker acceleration, allowing the
vehicle to respond promptly to changing road conditions. This responsiveness is
especially useful in urban environments where quick acceleration may be
necessary to merge into traffic or navigate around obstacles.
 Tailored Acceleration: The ability to shift gears manually enables drivers
to optimize their acceleration based on real-time needs. For instance, when
merging onto a busy highway, shifting down to a lower gear can provide a boost in
power, resulting in a smooth and confident entry into faster-moving traffic.
Conversely, during city driving, higher gears can be selected to maintain fuel
efficiency while still providing sufficient power to tackle inclines or navigate
through congested areas.
 Confidence in Control: This level of control instills confidence in drivers,
allowing them to make split-second decisions while driving. Whether needing to
accelerate to avoid a potential hazard or to pass another vehicle, the Grand i10’s
manual transmission allows for immediate responsiveness that can be crucial in
dynamic driving situations.
- Overall Driving Dynamics: The Grand i10 1.0 MT’s design and engineering
contribute to an overall driving experience that is characterized by agility and ease
of handling. Its compact size and lightweight construction play significant roles in
making it an enjoyable car to drive.
 Agility in Urban Environments: The small dimensions of the Grand i10
make it particularly well-suited for city driving. Drivers can easily navigate
through narrow streets, tight corners, and crowded parking lots. The steering
response is light and direct, enhancing maneuverability and making the car feel
nimble and lively.
 Comfort and Stability: Despite its compact size, the Grand i10 offers a
stable and comfortable ride. The suspension system is designed to absorb bumps
and imperfections in the road, providing a smooth driving experience. This balance
of comfort and agility ensures that drivers can enjoy their journeys without feeling
fatigued, whether they are commuting daily or embarking on longer trips.

Performance and Fuel Efficiency

- Fuel Consumption: Thanks to its efficient design, the manual transmission

optimizes fuel consumption, achieving an average of about 5.4 liters per 100
kilometers in mixed driving conditions. This is particularly beneficial for those
who prioritize cost-effectiveness in their daily commuting.
- Engine Power Control: The manual transmission empowers drivers to
effectively control engine power, optimizing performance in various driving
scenarios, whether accelerating on the highway or managing lower speeds in urban
traffic.

Safety Features

- Better Control: The manual transmission system enhances drivers' ability to

manage speed and acceleration, particularly beneficial in challenging driving
conditions. This feature is invaluable when navigating steep inclines or slippery
roads.
- Parking Assistance: The manual transmission provides the necessary
flexibility in tight parking situations, allowing drivers to adjust their speed with
precision when parking or making sharp turns, thereby improving overall safety.

Target Audience: The Hyundai Grand i10 1.0 MT 2018 is designed to appeal
to a diverse range of consumers, each with unique needs and preferences. Its
combination of affordability, practicality, and engaging driving experience makes
it a versatile choice in the compact car segment. Below, we explore the primary
target audiences for this model in greater detail.

- Young Consumers: The Hyundai Grand i10 1.0 MT 2018 particularly

resonates with young individuals who are seeking a vehicle that embodies a sense
of fun and adventure. This demographic values not only the aesthetic appeal of
their car but also the driving experience it offers.
 Fun and Engaging Driving Experience: Young consumers are often drawn
to vehicles that provide an exciting driving experience, and the manual
transmission of the Grand i10 allows them to engage more actively with their car.
The thrill of shifting gears manually enhances the driving feel, making it a more
enjoyable and dynamic experience. This model's sporty characteristics, combined
with its stylish design, make it an attractive option for first-time car buyers and
young professionals looking to make a statement.
 Affordability and Practicality: Budget-conscious young consumers
appreciate the Grand i10’s competitive pricing and low maintenance costs. As
many young people may still be in the early stages of their careers or pursuing
education, the financial benefits of owning a fuel-efficient vehicle that is also
stylish and modern make it an appealing option. The Grand i10’s blend of
practicality and fun ensures that young drivers can enjoy their independence
without compromising on style or functionality.
- New Drivers: The Hyundai Grand i10 1.0 MT 2018 is an excellent choice
for new drivers, providing them with a vehicle that helps build essential driving
skills and instills confidence behind the wheel.
 User-Friendly Manual Transmission: The manual transmission in the
Grand i10 is well-suited for beginners who wish to learn the intricacies of gear
shifting. This feature allows new drivers to gain hands-on experience, improving
their understanding of vehicle dynamics and control. The ease of shifting gears in
this model is conducive to learning, making it less intimidating for those who are
just starting their driving journey.
  Safety and Visibility: New drivers often prioritize safety features, and the
Grand i10 is equipped with essential safety measures, including airbags and anti-
lock braking systems. Additionally, its compact size and excellent visibility make
it easier for inexperienced drivers to navigate tight spaces and busy roads. This
combination of safety and user-friendly features allows new drivers to build their
confidence while enjoying the freedom of driving.
 Comfortable Interior: The spacious and comfortable interior provides a
welcoming environment for new drivers, allowing them to focus on learning
without feeling overwhelmed. The well-designed cabin and intuitive controls
enhance the driving experience, making it an ideal choice for those still mastering
the basics of operating a vehicle.
- Business and Taxi Use: The Hyundai Grand i10 1.0 MT 2018 is also highly
suitable for business applications, including use as a taxi or for small commercial
operations. Its practical features and fuel efficiency make it an excellent option for
operators looking to optimize their operational costs.
 Fuel Efficiency: The Grand i10’s manual transmission contributes to its
remarkable fuel efficiency, allowing taxi drivers and business operators to
minimize fuel expenditures. In an industry where every penny counts, the ability to
achieve excellent mileage helps drivers maximize their profits. The car’s fuel
economy makes it an attractive choice for those in the transportation sector,
ensuring that operational costs remain low while providing reliable service to
customers.
 Durability and Reliability: Known for its robust build quality, the Grand
i10 is engineered to withstand the rigors of daily use in a commercial setting. Its
reliability is a significant factor for taxi operators who require a vehicle that can
endure high mileage and constant use without frequent breakdowns or repairs. The
vehicle’s durability ensures that drivers can maintain a steady flow of income
without worrying about costly repairs or downtime.
  Passenger Comfort: The Grand i10 is designed with passenger comfort in
mind, featuring spacious seating and a well-structured interior. This is especially
important for taxi operators who aim to provide a pleasant experience for their
passengers. The comfortable seating and well-appointed cabin create an inviting
atmosphere, encouraging repeat business and positive customer feedback
 Chapter 2: THEORETICAL BASIS

2.1. Introduction to Hyundai i10 MT gearbox

Hyundai i10 MT transmission (manual transmission) is one of the important

parts in the vehicle's transmission system, allowing the driver to adjust the ratio of
power transmission from the engine to the wheels. This system not only helps the
car operate efficiently but also brings an enjoyable driving experience to the user.
Hyundai i10 uses two types of manual transmissions for the Epsilon engine and
one type of transmission for the U Common Rail Diesel engine, with optimal
design for performance and durability.

2.2. Structure of Hyundai i10 MT gearbox

2.2.1. Gearbox cover

The gearbox housing is made from aluminum alloy or steel, helping to reduce
weight while increasing durability. The case not only protects the internal
components but also functions to contain lubricating oil and oil level check
buttons.

2.2.2 Gears

Structure of gears: Gears in the Hyundai i10 MT transmission is designed to

withstand great pressure and friction. They are often made from alloy steel or other
load-bearing materials, ensuring durability and long-term performance. Each gear
has a different size and shape, depending on the gear it serves.

- Main gear: The largest gear, usually located on the primary shaft. It is
responsible for receiving force from the engine and transmitting it to other gears.
- Auxiliary gear: Usually smaller than the main gear, located on the secondary
shaft. They combine with the main gear to create the necessary gear ratio for each
gear.
- Synchronization gear: Used to synchronize the speed between gears when
shifting gears, helping the gear shifting process go smoothly.
32
 Function of gears: Gears in the Hyundai i10 MT transmission performs many
important functions:

- Changing gear ratio: By changing the connection between gears, the driver
can adjust the vehicle’s speed and torque.
- Power transmission: Gears help transmit power from the engine to other
parts of the transmission system, ensuring the vehicle moves efficiently.
- Synchronization: Synchronization gears help minimize collisions between
gears when switching between gears, thereby increasing the durability of the
gearbox.

Operating principle: When the driver moves the lever to the position
corresponding to each gear level:

- Level 1: The large gear on the primary shaft will mesh with the small gear
on the secondary shaft, creating the highest gear ratio to start the vehicle.
- Gear levels 2 to 5: Similarly, each gear level will use a different pair of
gears to adjust speed and torque according to driving needs.
- Reverse gear: When shifting to reverse mode, a pair of intermediate gears
will be used to reverse the direction of rotation of the secondary shaft, allowing the
vehicle to move in reverse.

2.2.3. Gearbox shaft

a. Structure

Primary Shaft:

- Function: The primary shaft is where the force from the engine is received
through the clutch. When the driver steps on the clutch, the clutch disconnects the
engine and transmission, allowing for shifting between gears without damaging the
gears.
- Structure: This shaft usually has a number of large gears attached to it.
When the motor rotates, the primary shaft also rotates.

33
 - Gear ratio: The gear ratio of the primary shaft affects the output torque and
speed. This ratio is designed to optimize performance for each gear.

Intermediate Shaft:

- Function: The intermediate shaft connects the primary shaft and the
secondary shaft. It receives force from the primary shaft and transmits force to the
secondary shaft through meshing gears.
- Structure: This shaft often has many smaller gears, helping to adjust the
transmission ratio between the primary and secondary shafts.
- Operating principle: When the primary shaft rotates, force will be
transmitted through pairs of gears on the intermediate shaft, causing it to rotate and
continue to transmit force to the secondary shaft.

Secondary Shaft

- Function: The secondary shaft is the last place to receive force before being
transmitted to the wheel. It is responsible for converting force from the
intermediate shaft into vehicle motion.
- Structure: This shaft often has smaller gears than the gears on the primary
shaft, helping to create a lower gear ratio, suitable for moving at high speeds.
- Impact on performance: The gear ratio of the secondary shaft is important in
determining the maximum speed of the vehicle. A low ratio will help the vehicle
reach higher speeds but with less torque.

b. Operating principle of axes

When the driver moves the lever to the position corresponding to each gear
level:

Level 1: The gear on the primary shaft meshes with the gear on the
intermediate shaft, creating the highest gear ratio to start the vehicle.

Gear levels 2 to 5: Each gear level will use a different pair of gears between
the axles to adjust speed and torque according to driving needs.
34
 Reverse gear: To move backward, an intermediate gear will be used to reverse
the direction of rotation of the secondary shaft, allowing the vehicle to move in
reverse.

2.3. Working principle of Hyundai i10 MT gearbox

2.3.1. The process of transmitting power from the engine

When the driver steps on the clutch, the clutch disconnects the engine and
transmission, allowing for shifting between gears without damaging the gears. The
force from the engine is transmitted through the clutch to the primary shaft.

2.3.2. Convert gear ratio

The Hyundai i10 MT gearbox allows the driver to switch between gears from
1 to 5 and reverse via the lever:

- Number 1: Used for starting and initial acceleration.

- Number 2: Suitable for faster acceleration under heavy load conditions.
- Number 3: Used for moving around the city.
- Number 4: Optimize high speeds on the road.
- Number 5: Save fuel at high speed.
- Reverse: Used to move backwards.

2.3.3. Operational situations

The driver may need to shift gears while stopped or while moving to optimize
engine performance and fuel economy.

35
2.4. Specifications

2.5. Power transmission diagram

Detailed description of the diagram:

36
 Engine: Where power and torque are produced.

Clutch: Disconnects the engine and transmission when the driver steps on
the clutch, allowing switching between gear levels.

Primary Shaft: Receives force from the engine through the clutch. This
shaft has a large gear, transmitting power to the intermediate shaft.

Large gear: The gear on the primary shaft meshes with the gear on the
intermediate shaft, creating the highest gear ratio for the 1st gear.
37
 Intermediate Shaft: Connects between the primary shaft and secondary
shaft, transmitting force from the primary shaft to the secondary shaft through
gears.

Small gear: The gear on the intermediate shaft meshes with the gear on the
secondary shaft, helping to adjust the transmission ratio for different gear levels.

Secondary Shaft: Transmits force outward to control the wheel.

Reverse gear: When the lever is in the reverse position, a special pair of
gears is activated to reverse the direction of rotation of the secondary shaft,
allowing the vehicle to move in reverse.

2.6. Advantages and disadvantages of Hyundai i10 MT transmission

The Hyundai i10 MT transmission, with a manual transmission design, brings

many benefits as well as some limitations to users. Below is a detailed analysis of
the advantages and disadvantages of this gearbox.

Advantages:

- Fuel economy: Manual transmissions are often more fuel efficient than
automatic transmissions. This is because the driver can better control gear changes
and maintain engine rpm at an optimal level, minimizing fuel consumption during
operation.

- Better control: Drivers can adjust torque and speed more easily in different
driving situations, especially when rapid acceleration is required or when traveling
off-road hills and mountains.

- Exciting driving feeling: The manual transmission provides a more active

driving feel, helping the driver feel more clearly about the vehicle’s engine and
acceleration. This creates a more enjoyable driving experience for those who love
sporty driving.

38
 - Low maintenance costs: Manual transmissions are often easier to maintain
and repair than automatic transmissions. Manual transmission parts are simpler,
helping to reduce costs when needing replacement or repair.

- High durability: Manual transmissions are often more durable due to their
simpler design and fewer electronic parts than automatic transmissions. This helps
minimize the possibility of damage during use.

Disadvantages:

- Requires higher driving skill: Manual transmission requires the driver to

have good skills to operate effectively. Switching between gears requires attention
and coordination between the clutch and accelerator].

- Fatigue in heavy traffic: Continuously pressing the clutch and shifting gears
can cause driver fatigue in heavy traffic conditions, especially when having to stop
and start many times.

- Difficulty for new drivers: Drivers who are new or unfamiliar with using a
manual transmission may have difficulty controlling the vehicle, leading to
“scratching” when shifting gears or not. Speed control.

- Limited in some situations: In some situation such as towing heavy loads or

traveling on difficult terrain, a manual transmission may not be as flexible as an
automatic transmission.

39
 Chapter 3: GEARBOX DESIGN AND CALCULATION
3.1. Preliminary parameters of Grand i10 gearbox

3.1.1. Given value.

Hyundai has released essential specifications for the 1.0 manual transmission
in their 2018 Grand i10 model. These specifications encompass critical
performance factors such as the engine’s maximum power output, torque, and
speed, along with the transmission ratios for each individual gear. Additionally, the
tire specifications are provided, which play a significant role in determining the
overall vehicle dynamics. These parameters are crucial for further technical
calculations and assessments. The table below offers a comprehensive summary of
all the necessary data points needed for future analysis.

Pe max 5500 Rpm

Me max 94 N.m
v max 155 Kph
i1 3.727
i2 2.056
i3 1.280 helical
i4 0.964
i5 0.774
iR 3.636 spur
i final 4.8

Wheel & tyre 165/65R14

- Pemax: maximum engine power.

- M emax: maximum engine torque.

- i 1 , i 2 ,i 3 ,i 4 , i 5 ,i R , i final : ratio of first, second, third, fourth, fifth, reverse and final
drive respectively.
40
 All the gear pairs in the 5-speed transmission are of the cylindrical helical
type, with the exception of the reverse gears, which utilize a cylindrical spur
design.

Based on the provided wheel and tire specifications, key dimensions such as
tire width, tire height, rim diameter, and wheel radius can be determined as
follows:

Tyre width (w ) 165

Tyre height (h) 165 ×65 %=107.25

mm
Rim diameter (d R) 14 inch=355.6

dR
Radius of Wheel (r b =h+ ) 285.05
2

3.1.2. Traction conditions and grip conditions.

We calculate the first gear transmission ratio based on both drag and grip
conditions to ensure optimal performance and traction:
ψ max × G× r b
- Drag condition for first gear: i1 ≥ M × i × i × η
e final
max
cc

G φ ×φ × r b
- Grip condition for first gear: i 1 ≤ M × i × i × η
e final
max
cc

In there:
ψ max : The maximum drag coefficient of the road surface is calculated as

ψ max =f + tg( α max ) , where f is the rolling resistance coefficient of the road, f =0.02, and

α max is the maximum slope angle, α max =15° . Thus, the maximum drag coefficient is:

ψ max =0.02+tg(15 °)=0.29 .

G : The weight of the car in Newtons (N ) is given byG=10 × m, where m is the

kerb weight of the Grand i10, m=935 kg. Therefore, G=10 × 935=9350 N .

η : The powertrain efficiency is η=0.85.

41
 Gφ: The weight of the car distributed over the driving axle is important for

calculating grip. As the Grand i10 is a front - engine, front - wheel-drive vehicle,
60% of the car’s total weight is on the front axle. Assuming cos (15 °)≈ 1, the grip
weight on the front axle is Gφ=0.6 × G=5610 N .

i cc : The ratio of the auxiliary gearbox (or distribution box) at high gear. Since

the Grand i10 lacks an auxiliary gearbox, icc=1.

φ : The grip coefficient between the active wheels and the road surface is

chosen as φ=0.9 to ensure sufficient grip.

As a result, the first gear ratio i 1 should be i 1 ≥ 2 for the drag condition and
i 1 ≤ 3.75 for the grip condition. Therefore, selecting i 1=3.727 satisfies both safety

conditions.

3.2. Gear parameters selecting and calculating

3.2.1. Gear teeth selecting

Based on the given ratio, the gear teeth are selected to minimize power loss,
reduce the size of the gearbox, and maximize gear durability. This careful selection
ensures efficient transmission performance, compact design, and long-lasting
reliability of the gears:

Zn Zn'

41 Teeth
As i1=3.727= 11 →Choose Z1 , Z '1 11 41

37 18 37
As i2=2.056= 18 →Choose Z 2 , Z '2

42
 32
As i 3=1.280= 25 →Choose Z3 , Z '3 25 32

27
As i 4 =0.964= 28 →Choose Z 4 , Z '4 28 27

24
As i 5=0.774= 31 →Choose Z5 , Z '5 31 24

40
As i R =3.636= 11 →Choose Z R , Z 'R 11 40

3.2.2. Center distance between shafts and gear modulus selecting

The gear modulus for the spur gear can be selected based on the standard
values of modulus, which are determined by the maximum engine power. The
table below provides the recommended modulus values according to the engine’s
power output:

M emax (Nm) m

50 ÷ 100 2.25 ÷ 2.5

100 ÷ 200 2.75 ÷ 3

200 ÷ 400 3 ÷ 3.75

400 ÷ 800 3.75 ÷ 4.5

800 ÷ 1000 4.5 ÷ 6

Given the maximum engine torque provided by the manufacturer,

M emax=94 Nm, the modulus for the reverse gear can be selected as m=2.5 . Using this

modulus value, the center distance between the two shafts can be calculated using
the following formula:

a=0.5 m×(Z R + Z R ')=63.75 mm

However, this center distance is specifically suitable for the reverse gears and
needs to be reselected to accommodate all gear pairs. Therefore, the center distance
is set at a=65 mm.

43
 For cylindrical helical gears, the normal modulus is necessary for further
dimensional calculations. To determine a suitable modulus, we can select a
temporary helix angle. Here, we choose β 2=17 ° . The normal modulus is calculated
using the formula:
2 ×cos β 2 ×a
m n=
Z 2+ Z 2 '

In this case, the normal modulus is determined to be mn=2.25 , which ensures a

safe operating angle for the gears.

3.2.3. Gear dimension calculating

After selecting the appropriate gear teeth, center distance, and modulus for
each gear pair, we can calculate the helix angle, normal pitch, pitch circle diameter,
addendum circle diameter, and dedendum circle diameter using the following
formulas:
'
Z+ Z
- Helix angle: β=arccos (m× )
2a

- Normal pitch: p=π × m

m
- Pitch circle: d= cos ( β ) × Z

- Addendum circle: d a =d +2 m

- Dedendum circle: d d =d−2.5 m

Z1 Z1 ' Z2 Z2' Z3 Z3 ' Z4 Z4' Z5 Z5 ' ZR ZR '

βn 25.8 17.8 9.4 17.8 17.8 0.0

Pn 7.0 7.07 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.07 mm

7 7 7 7 7 7 7 7 7 7

44
 27. 102. 42. 87. 57. 73. 66. 63. 73. 56. 27. 100.
dn
5 5 5 5 0 0 2 8 3 7 5 0

32. 107. 47. 92. 61. 77. 70. 68. 77. 61. 32. 105.
d an
0 0 0 0 5 5 7 3 8 2 5 0

21. 36. 81. 51. 67. 60. 58. 67. 51. 21.
d dn 96.9 94.4
9 9 8 4 4 6 2 6 1 9

3.3. Gear durability calculation

3.3.1. Force acting on gear calculation

Force Spur Gear Helical Gear

2 Mt 2 Mt
1 Tangential P n= P n=
d d

tg ( α )
2 Radial Rn =P n . tg (α ) Rn =P n .
cos ( β n )

3 Axial Qn=0 Pn=P n . tg (β n)

Where:

- M t : Torque calculated on the gearbox shafts

- α : Original propeller angle

- β n: Slope angle of the n - th gear

For each gear pair, the number of teeth ( Z ) and calculated torque ( M t ) are
chosen as follows:

- For the first pair of helical - toothed cylindrical gears, we select an active
gear with Z1 =11 on the primary shaft, where M t =M emax .

- For the second pair of helical - toothed cylindrical gears, we choose an

active gear with Z 2=18 on the primary shaft, with M t =M e x. ma

45
 - For the third pair of helical - toothed cylindrical gears, we select an active
gear with Z3 =25 on the primary shaft, ensuring M t =M emax .

- For the fourth pair of helical - toothed cylindrical gears, the active gear is
chosen as Z 4=28 on the primary shaft, where M t =M emax .

- For the reverse gear, a spur - toothed cylindrical gear with Z R=11 is selected
on the primary shaft, so M t =M emax .

- For the pair of helical toothed cylindrical gears set at number 5, we choose
to calculate the active gear with Z5 =31, located on the primary shaft, so M t =M emax

Pn Rn Qn

1st Gear 6836.4 2764.7 3311.0

2nd Gear 4418.8 1689.5 1422.0

3rd Gear 3297.2 1216.5 546.6 N

4th Gear 2840.7 1086.1 914.1

5th Gear 2562.8 981.0 825.7

Reverse 6836.4 2488.2 0.0

46
 3.3.2. Bending stress calculation

The bending stress at the critical section is calculated using the following
formula, based on the reference from (Tính toán thiết kế ô tô - Đặng Quý)
P. K
σ u=
b. p. y

- P: Tangential force acting on the teeth at the center of engagement (MN)

- b : Gear width (0.013 m)
- t n: Normal pitch (m)
- y : Tooth form factor (obtained from Table 4.1 in Tính toán thiết kế ô tô -
Đặng Quý)
- K : Additional coefficient accounting for factors such as stress concentration
in the teeth, meshing coincidence, contact surface friction, and deformations in
bearings and shafts.

The normal tooth pitch is calculated using the formula: t n=π .mn , where mn is
the normal module.

The tooth shape coefficient y for non-adjustable gear pairs is selected. For
spur gears, the actual number of teeth Z is used, while for helical gears, the
Zi
equivalent number of teeth Z td is chosen: Z td= 3
cos ⁡( β)

The additional coefficient K for spur gears is 1.12 and for helical cylindrical
gears is 0.75. Then we simply have:
P
- For spur gear: σ u=0.36 b . m . y
n

P
- For helical gear: σ u=0.24 b . m . y
n

47
 Gears pair 1-1' 2-2' 3-3' 4-4' 5-5' R
Z 11 18 25 28 31 11
Z td 15.1 20.9 26.0 32.5 35.9

0.12
y 0.152 0.136 0.142 0.140 0.098
6

4.41
P(kN ) 6.836 3.297 2.841 2.566 6.836
9
σ u ( MN /m 2) 367 288 193 163 150 850
Z' 41 37 32 27 24 40
Z td ' 56.2 42.9 33.3 31.3 27.8

y 0.159 0.15 0.144 0.142 0.132 0.148

4.41
P(kN ) 6.836 3.297 2.841 2.566 6.836
9
σ u (MN /m 2) 351 241 182 163 159 653

To ensure durability, the calculated stress must meet the following conditions:
σg
σ u≤
1.3

- σ g: Stress causing fracture (based on material strength)

The tooth bending stress for gearbox gears typically falls within the following
limits:

- Gear pairs 1 and 2: 350 ÷ 840 MN /m ²

- Gear pairs 3, 4, and 5: 150 ÷ 400 MN /m²
- Reverse gear pair: 300 ÷ 1200 MN /m ²

These limits ensure that the gears maintain durability under bending stress
conditions.

3.3.3. Contact stress calculation

48
 σ tx=0,418. cos (β)
√ '
P. E 1 1
.( + )
b . sin(α ). cos (α ) 1 r 2
r

In there:

- β : tooth slope angle

- P: tangential force (MN)
- E : modulus of elasticity for steel, E=( 2÷ 2 , 2 ) × 105(MN /m2).

Choose E=2.105(MN/m2).

- b : tooth contact length(0.013 m)

- r 1 , r 2 : rolling circle radius of active gear and passive gear (m )

- α : original prophin angle(20 °)

The contact stress for gearbox gears typically falls within the following
ranges:

- [σtx]=1000÷ 2500 MN /m² for helical gears

- [σtx]=1500÷ 3000 MN /m² for spur gears

These limits ensure that the gears meet durability conditions under contact
stress.

3.4. Shaft design and calculation

Choose the shaft material as carburized 12XH3A steel with [σ] = 60 MPa.
The preliminary dimensions of the shafts are determined as follows:

49
 Primary Shaft:

- d 1=5.3 √3 (M emax )=5.3 √3 94=24.1 mm. Hence, choose d 1=25 mm .

d1
- Primary shaft length: l 1= =139 mm
0 ,18

Additionally:

- d 1=(0.16 ÷ 0.18)× l 1, choose d 1=0.18× l 1

- Secondary Shaft: d 2=0.45× a=0.45 ×65=29.25 mm. Hence, choose d 2=30 mm .
d2
- Secondary shaft length: l 2= 0 , 21 =143 mm

Additionally:

- d 2=(0.18 ÷ 0.21)×l2, choosed 2=0.21× l2

3.5. Bearings design and durability calculation

3.5.1. Bearings design parameters

The sizes of the shaft bearings selected for the genuine Grand i10 1.0 manual
gearbox are as follows:

- Primary shaft bearing:

+ Inner diameter (d )≈ 0.45× a=0.45 ×65=29.25 mm

+ Outer diameter (D)≈ 0.90 × a=0.90 ×65=58.5 mm

+ Width (B)≈ 0.22 × a=0.22 ×65=14.3 mm

+ Bearing size: 29.25 ×58.5 ×14.3 mm

- Secondary shaft rear support bearing:

+ Inner diameter (d ) ≈ 0.40× a=0.40 ×65=26 mm

+ Outer diameter (D)≈ 0.90 × a=0.90 ×65=58.5 mm

+ Width (B)≈ 0.22 × a=0.22 ×65=14.3 mm

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 + Bearing size: 26 ×58.5 × 14.3 mm

- Secondary shaft resting on the primary shaft:

+ Inner diameter (d ) ≈ 0.23× a=0.23 ×65=14.95 mm

Where:

- D : outer diameter of the ball bearing

- d : inner diameter of the ball bearing

- B: width of the ball bearing

3.5.2. Bearings durability calculating

The durability of the bearing is determined by the capacity coefficient, which

reflects its workability and longevity. The capacity coefficient (C) is calculated
using the following formula:C=Re × K k × K d × K o /i × ( n ×h )0.3

Where:

- K k : Coefficient of the effect of temperature on the durability of bearings.

Choose K k =1 K k =1 under normal conditions.
- K d : Dynamic load coefficient of the bearings. Considering that the bearing is
subjected to medium collisions, the dynamic load coefficient is K d =1.2

−K o / i: Rolling race coefficient of the bearings. For calculations when the outer

race is rolling, use K o =1.1. For calculations when the inner race is rolling, use K i=1
.

- h: Working period of the bearings between two overhauls of the gearbox. To

determine the working period, the average speed of the most used gear is selected:
v aver =40 kph . The distance traveled between two overhauls for the Grand i10 is

approximately S=100,000 km.The working period of the bearings is calculated using

S 100,000
the formula: h= v = =2500 (hours)
aver 40

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 - n: Revolution speed of the bearings (in rpm). The speed is determined using
aver hv cc ×i ×i ×i
final
the formula: n= r × 0.377 ×2 π , with i h is the ratio of the most used gear,
b

i h=i 5=0.774 ; since Grand i10 has no auxiliary gearbox, i cc =1. Hence
106
40 × × 0.774 × 4.8
60
n= =3668 rpm.
285.05
× 0.377 ×2 π
1000

- Re: Equivalent force acting on the bearings. To calculate this force, the
coefficient of revolution of the bearings, the converted radial force acting on the
bearings, and the working time coefficient of the bearings must be determined. By
applying these parameters, the capacity coefficient C can be calculated, allowing
for the assessment of the bearing's durability under operational conditions.

The coefficient of Working

revolution of Conversed radial force on times

in bearings: Rcn =Rn +mc × Qn coefficient of
bearings: N n= ih bearings:T n

11042.
1st Gear 4.82 0.1%
2

2nd Gear 2.66 5244.6 0.5%

N
3rd Gear 1.65 2582.8 2%

4th Gear 1.25 3371.5 5%

5th Gear 1.00 3045.2 80%

Using the calculated parameters, the equivalent force is determined by th

formula:

√∑
5
3.33 3.33
Re = N n ×T n × R cn =3324.1( N )
n=1

Therefore, when the outer race of the bearing is rolling, the bearing capacity
coefficient is calculated as:

52
 C o=R e × K k × K d × K o × ( n × h ) =1059.2 kNm .
0.3

Conversely, when the inner race of the bearing is rolling, the capacity
coefficient is given by: C i=Re × K k × K d × K i × ( n× h )0.3 =962.9 kN . m

53
 INFERENCE

The manual transmission of the Hyundai Grand i10 2018 1.0 MT not only
delivers an engaging driving experience but also enhances performance and safety
for users. With its outstanding features, intelligent design, and practicality for both
personal and commercial use, this manual transmission significantly contributes to
the model's success in the competitive Vietnamese automobile market. As the
automotive landscape continues to evolve, the Grand i10 remains a popular choice,
embodying reliability, efficiency, and driving pleasure.

In conclusion, the design and calculation of the manual transmission gearbox

for the Hyundai Grand i10 2018 1.0 MT emphasize the importance of precision
engineering and adherence to performance standards. This study carefully
considered the technical specifications, including gear ratios, material selection,
and structural durability, to ensure optimal functionality and reliability of the
gearbox.

The manual transmission system was analyzed to balance engine power

delivery, fuel efficiency, and vehicle performance under varying operating
conditions. Through comprehensive calculations and design assessments, the
gearbox was tailored to meet the requirements of the 1.0-liter engine, providing
smooth gear shifts, enhanced driving comfort, and long-term durability.

This work not only highlights the intricate process of designing a key
automotive component but also reinforces the importance of integrating theoretical
principles with practical applications in automotive engineering. By achieving the
design objectives, the project contributes to the development of efficient and
reliable transmission systems, which are essential in modern vehicles.

54
 REFERENCES

1. Car Deal Canada, 12/08/2024, Who Owns Hyundai?

Link: https://www.cardealcanada.ca/who-owns-hyundai/
2. Kim Byung-wook, 14/10/2020, Hyundai Motor’s journey from 1940s to
2020
Link: https://www.koreaherald.com/view.php?ud=20201014001043
3. CarDekho, Hyundai Grand i10 Specifications
Link: https://www.cardekho.com/hyundai/hyundai-grand-i10-
specifications.htm
4. GVS. ThS. Đặng Quý - Giáo trình Lý thuyết ô tô - Ho Chi Minh city
University of Technology and Education
5. Larry Collin, 18/12/2019, The Evolution of Transmission.
Link: https://www.transmissionsolympia.com/the-evolution-of-
transmissions/#:~:text=1894&text=Emile%20Levassor%20and%20Louis
%2DRene,point%20for%20contemporary%20manual%20transmissions
6. Hyundai Worldwide website - car - i10 Highlights
Link: https://www.hyundai.com/worldwide/en/cars/i10/highlights

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