Submitted by Esampalli Ravi Kumar - 10521A0314 Musunuri Madhu Babu - 10521A0333 Gulipalli Ravi Teja - 10521A0317 Paruvu Venkata Rajendra - 10521A0339
Submitted by Esampalli Ravi Kumar - 10521A0314 Musunuri Madhu Babu - 10521A0333 Gulipalli Ravi Teja - 10521A0317 Paruvu Venkata Rajendra - 10521A0339
Submitted by Esampalli Ravi Kumar - 10521A0314 Musunuri Madhu Babu - 10521A0333 Gulipalli Ravi Teja - 10521A0317 Paruvu Venkata Rajendra - 10521A0339
BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING
(2010-2014)
SUBMITTED BY
CERTIFICATE
This is to certify that the project report entitled “DESIGN AND FABRICATION OF
SPUR GEAR ON CNC MACHINE” is a bonafied record of,
ACKNOWLEDGEMENT
Place: Visakhapatnam
Andhra Pradesh.
Page |4
CONTENTS
DESCRIPTION Page No
1. Project abstract 5
2. Introduction 6
2.1 Over view of Visakha Steel Plant 6
2.2 Main units of VSP 7
1. PROJECT ABSRACT
CNC technology stands as the state of art technology for the manufacturing of job and
shop products with so many tangible and intangible applications resulting through this
adoption, by using CNC controllers, there is a remarkable increase in the quality of products
as well as it offers high flexibility. It increases the productivity and reduces lead time and
scrap generated. To conciliate the investment on CNC, its usage, operating cost and
maintenance must be in balance with the machine cost .So it demands excellent operational
skills and regular maintenance of the machine components .In this the main aspect of
preparing this note is to brief the operation and maintenance of CNC machines being used in
Visakhapatnam Steel Plant.
CNC machines at VSP are used to generate Roll passes on new rolls & redress the
used rolls from the mills. Using “WALDRICHSEIGEN” make with SINUMERIK 850-T
controller lathes and “HERKULES” with SINUMERIK 3-T controller lathes. Simultaneously
CNC Milling machines with “SINUMERIK 810-M” controllers are used for machining the
guide offs of type VVS-I&VVS-II using part programming. In this report a detailed study of
the Numerical part programming used in the CNC machines and the theory of rolling, roll
pass designs used in the rolling mills of VSP.
The entire report has been a keen study about the programming, design and
fabrication of an involute spur gear. And a part programming is formulated for cutting the
gear on CNC Milling Machine.
Page |6
2. ABOUT VSP
2.1. AN OVERVIEW OF THE ORGANISATION:
blending, stacking & reclaiming facilities viz. Wagon Tipplers, Ground & Track Hoppers,
Stock yards Crushing plants, Vibrating screens Single/twin boom stackers, wheel on boom
and Blender recliners. In VSP Peripheral unloading has been adopted for the first time in the
country.
Coal is converted into coke by heating the prepared coal blend charge in the coke ovens
in the absence of air at a temperature of 1000oC-1050oC for a period of 16/18 hours. The
volatile matter of coal liberated during carbonization is collected in gas collecting mains in
the form of raw coke oven gas passing through stand pipes and direct contact cooling with
ammonia liquor spray. The gas cooled from 800oC to 80oC is drawn to Coal Chemical Plant
by Exhauster. The residual coke is pushed out of the oven by pusher car through a guide into
coke bucket. The red-hot coke is taken to coke dry cooling plant for cooling.
FACILITIES:
There are 4 batteries, each having 67 ovens.
The volumetric capacity of each oven is 41.6 m3.
Dry Coal charge /Oven is 32 t
Page |9
SALIENT FEATURES
1. Largest and technologically unique Coke Oven Batteries in the country at the
time of commissioning.
2. 7 metre tall coke ovens batteries.
3. Selective crushing of coal to improve the coke quality.
4. 100% Dry Quenching of coke using Nitrogen gas.
5. Power generation, from the waste heat recovered, at BPTS (Back Pressure
Turbine Station).
CAPACITY
Production capacity – 2.635 Mt of Gross coke per annum (2.261 Mt of BF Coke per annum)
SINTER PLANT:
Sintering is done in 2 nos. Of 312 sq.metre, Sinter Machines of Dwight Lloyd type by heating
the prepared feed on a continuous metallic belt made of pallets at 1200 – 1300 0C.
Hot Sinter discharged from Sintering machine is crushed to +5 mm – 50mm size and cooled
before dispatching to Blast furnaces.
BLAST FURNACE:
Hot Metal is produced in Blast
furnaces, which are tall vertical
furnaces. The furnace is named as
Blast Furnace as it is run with blast
at high pressures & temperature.
Provision exists for granulation of 100% liquid slag at blast furnace cast house and utilization
of blast furnace gas top pressure (1.5 – 2.0 atmospheric pressure) to generate 12 MW of
power in each furnace by employing gas expansion turbines. The two furnaces with their
novel circular cast house and four tap holes each are capable of producing 9720 tons of hot
metal daily or 3.4 million tons of low sulphur hot metal annually.
Steel is an alloy of iron with carbon up to 1.8%. Hot metal produced in Blast furnaces
contains impurities such as carbon (3.5 – 4.25% Silicon (0.4% - 0.5%), Manganese (0.3 -
0.4%), Sulphur (0.04%max) and phosphorous (0.14%max) is not suitable as a common
engineering material. To improve the quality the impurities are to be eliminated or decreased
by oxidation process.
VSP produces steel employing three numbers of top blown Oxygen Converters called LD
converters (L & D stand for Linz & Donawitz – two towns in Austria where this process was
first adopted) or Basic Oxygen Furnaces / Converters .Each converter is having 133 cu.metre
volumes capable of producing 3 Million Tons of Liquid Steel annually .Besides Hot Metal,
Steel scarp, Fluxes such as calcined line or Dolomite form part of the charge to the
converters.99.5% pure Oxygen at 15- 16 KSCG pressure is blown in the convergent through
oxygen lance having convergent Divergent copper nozzles at the blowing end. Oxygen
oxidizes the impurities present in the process heat is generated by exothermic reaction of
Oxidation of metalloids viz.Si,Mn,P and Carbon and temperature rises to 17000C enabling
refining & Slag formation.
is first routed through, argon rinsing station, IRUT (Injection Refining & Up temperature) /
Ladle furnaces.
Continuous casting may be defined as teeming of liquid steel in a mould with a false bottom
through which partially solidified ingot / bar (Similar to the shape & cross section of the
mould) is continuously withdrawn at the same rate at which liquid steel is teamed in the
mould. Facilities at a continuous casting machine include a lift and Turntable for ladles,
Copper mould, mould oscillating system tundish, primary & secondary cooling arrangement
to cool the steel bloom. Gas cutting machines for cutting the blooms in required lengths (Av.
6 meters long).
At VSP we have six – 4 strand continuous casting machines capable of producing 2.82
million tons / year blooms of size 250 X 250 mm and 250 X 320 mm. Entire quantity of
molten steel produced (100%) is continuously cast in radial bloom casters which help in
energy conservation as well as production of superior quality products.
P a g e | 13
ROLLING MILLS:
Blooms produced in SMS-CCD do not find many applications as such and are require to be
shaped into a products such as billets, rounds, squares, angles (equal & unequal), channels, I-
PE beams, HE beams, Wire rods and reinforcements bars by rolling them in, three
sophisticated high capacity, high speed, fully automated rolling mills, namely Light and
Medium Merchant mills (LMMM) wire rod mill (WRM) and Medium Merchant and
structural Mill (MMSM).
All the above mentioned rolling mills are explained in the next page.
LMMM comprises of two units. In the Billet/ Break down mill 250 X 320 mm size
blooms are rolled into Billets of 125 X 125 mm size after heating them in two nos. of
walking beam Furnaces of 200 Tons /hr. capacity each. This unit comprises of 7
stands (2 horizontal 850 X 1200mm) and 5 alternating vertical & horizontal stands
(730 X 1000mm & 630 X 1000mm) .Billets are supplied from this mill to Bar Mill of
LMMM & Wire Rod Mill.
P a g e | 14
The billets for rolling in bar mill of LMMM are first heated in 2-strand roller hearth
furnace of 200 T/h capacities to temperature of 11500C - 12000C. The bar mill
comprises of 26 stands – 8 stand double strand roughing train,2 nos.of 5 stands,
double stand intermedial train & two nos. 4 stand single strand finishing trains . the
mill is design to produce 7,10,000 tons per annum of various finished products such
as rounds, rebar, squares, flats, angles, and channels besides billets for sale.
Wire Rod Mill is a 4 strand, 25 stands fully automated & sophisticated mill. The mill
has a four zone combination type reheating furnace (walking beam cum walking
hearth) of 200 TPH capacity for heating the billets received from billet mill of
LMMM to rolling temperature of 12000C. The heated billets are rolled in 4 strands.
No twist continuous mill having the following configuration.
The mill produces rounds in 5.5 -12 mm range and rebars in 8-12 mm range.
The mill is equipped with standard and retarded stelmore lines or producing high
quality Wire rods in Low , Medium &High Carbon grade meeting the stringent
National & international standards viz. BIS, DIN, JIS, Bs etc., and having high
ductility, uniform grain size, excellent surface finish.
P a g e | 15
Roughing train having 8 stands (4 two high horizontal stands, 2 vertical stands
and 2 combination stands).
Intermediate train has 6million stands as per detail given below.
2 high horizontal stands.
2 combination stands.
2 horizontal stands / two universal stands.
The feed material to the mill to 250X250 mm size blooms, which is heated to rolling
temperatures of 12000 c in two walking beams furnaces each of 130 tons per hour
capacity. The mill is capable of producing 8,50,000 tons of rounds, squares, flats,
angles, (equal & un equal), T-bars, channels, IPE beams / HE beams (Universal
beam) having high strength & close tolerances.
P a g e | 16
Two decentralized roll shops are envisaged in the department for catering to the needs of the
three rolling mills.
Roll shop-1 comprises of a Roll turning shop, Bearing shop, a specialized repair shop and
roll storage area catering to the needs of LMMM and WRM. Roll turning shop is equipped
with six CNC lathes, CNC template milling machine, Notch milling machine and a Branding
machine etc.
The basic function of roll turning shop is to initially turn the grooves on roll barrel as per the
groove drawings and distribution schemes according to rolling programs of the mills. Re-
turning/ redressing of the used rolls at frequent intervals depending on their usage and service
in the mill.
The grooved rolls are assembled with bearings and chocks in the bearing shop. Used bearings
are dismantled, cleaned, inspected, serviced and reassembled on the rolls at regular intervals.
Separate bearings for taking radial loads and axial loads are used and in specialized repair
shop caters the guide requirements of LMMM and WRM.
Roll shop-2 comprises of Roll turning shop, Bearing shop and Guide shop catering to the
requirement of MMSM. This Roll turning shop is equipped with six CNC Machines for
grooving new rolls as well as redressing. The grooved rolls are assembled with bearings in
the bearing shop. Chocks with bearings serviced periodically. Assembly and service and
repair of guides, preparation of strippers used in rolling of angles, channels, and beams is
done in guide shop.
ARS – Area Repair Shop caters few spares of all the three rolling mills and roll shops
4. INTRODUCTION TO CNC:
4.1. HOW CNC WORKS:
Sequence of events leading to the machining of a part in point to point positional positioning
1. The necessary information for numerical control can often be extracted from
engineering drawing with little or no calculations. For this purposes, the part is
considered as being in a quadrant of rectangular co-ordinates .The dimensions of all
the important details are given from the data point on X and Y axes
3. After the manuscript is prepared, the information has to be kept in hard disk of
programming transfer unit consisting DNC system to the controller medium (punch
type etc.,) which is done on same automatic writing and tape perforating machines
P a g e | 18
Measuring system record when the position of the work piece or tool indicated on the
part program has been reached. Function such as lubrication, coolant on/ off and
work piece clamping are activated using PLC (Programmable Logic Controller)
through relays & contactor at electrical panel.
CNC controllers have several choices for operation. These include polar coordinate
command, cutter compensation, linear and circular interpolation, stored pitch error,
helical interpolation, canned cycles, rigid tapping, and auto-scaling. Polar coordinate
command is a numerical control system in which all the coordinates are referred to a
certain pole. The position is defined by the polar radius and polar angle. Cutter
compensation is the distance you want the CNC control to offset for the tool radius
away from the programmed path. Linear and circular interpolation is the programmed
path of the machine, which appears to be straight or curved, but is actually a series of
very small steps along that path. Machine precision can be remarkably improved
through such features as stored pitch error compensation, which corrects for lead
screw pitch error and other mechanical positioning errors. Helical interpolation is a
technique used to make large diameter holes in work pieces. It allows for high metal
removal rates with a minimum of tool wear. There are machine routines like drilling,
deep drilling, reaming, tapping, boring, etc. that involve a series of machine
operations but are specified by a single G-code with appropriate parameters. Rigid
tapping is a CNC tapping feature where the tap is fed into the work piece at the
precise rate needed for a perfect tapped hole. It also needs to retract at the same
precise rate otherwise it will shave the hole and create an out of spec tapped hole.
Auto scaling translates the parameters of the CNC program to fit the work piece.
JOB
VELOCITY
FEEDBACK
TABLE
POSITIONAL FEEDBACK
D N C LINK
TAPE READER
OTHER DEVICES
MACHINE ELEMENTS
I/P DISPLAY UNIT
INPUT/OUTPUT
O /P KEYBOARD
FLOPPY DISC / CD
JOB
VELOCITY
FEEDBACK
TABLE
D N C LINK
TAPE READER
OTHER DEVICES
MACHINE ELEMENTS
I/P DISPLAY UNIT
INPUT/OUTPUT
O /P KEYBOARD
FLOPPY DISC / CD
P a g e | 20
CNC Controller consist of various electronic cards such as Memory Board, NC-PLC
communication Board, Input-Output Board, Video Board, PLC-CPU board,
MCP(Machine control Panel), OCP (Operator Control Panel), Display unit etc.
In CNC System Part program is feed through manual or through program transfer
device like digital instrument & DNC (Distributed Network Controller) system. This
part program stored in RAM memory of CNC controller. When machine is work in
automatic mode the part program is called. Part program commands are executed by
NC controller and give signal to Servo-drives, PLC etc.
In above CNC system block diagram commands are generated by CNC controller fed
to Servo drive for axis movement. Servo drive generate the electrical power to move
the servo motor for axes movements. In Servo loop the Tacho-generator which is
coupled with servo motor give the velocity feedback signal to Servo drive .This
system is known as velocity feedback system. For positioning of axis the encoder or
Linear Scale-Transducer give positional feedback system to CNC controller. Apart
from the positional command spindle CW/CCW, coolant ON/OFF, Tool change,
Feed, G codes are executed by CNC controller & give signal to PLCs.
MEMORY
SYSTEM
PROGRAM
SOFTWARE
PLC
MAIN MACHINE
INTERFACE DRIVE
PROCESSOR
JOG Mode: In this mode machine is operated in manually. In JOG mode machine
moves in respective direction of axis when key is pressed. This mode is normally use
for machine setting. When switch is not pressed machine cannot move. Axis feed can
be change by feed override switch.
REF Mode: In this mode machine is referenced before operating the CNC machine
in Automatic mode (programming mode), machine needed to be referenced.
Reference means machine zero position. It is very necessary to reference M/c because
during power off CNC system loose its positional value.
contains various codes like that the numeric value of axis position, tool command,
spindle rotation, spindle speed, coolant on/off, G-codes, M-codes, T-codes etc.
INCR 1, 10,100,1000,10000 Mode: In this mode machine move in 1, 10, 100, 1000,
10000 microns when switch is pressed with respect to direction of axis. This mode is
normally is used for fine setting of jobs.
MDI Mode: This mode in known as manual data input mode .In MDI mode machine
execute the program block .MDI mode normally is for small program. Like Tool
change Pallet change, Spindle ON /OFF etc.
4.3.3 ZERO OFFSET: The actual values are referred to the machine zero after a reference
point approach. The machining program of the work piece refers to the work piece zero.
Machine zero and work piece zero need not be identical. Depending on the type of work
piece and the way it is clamped, the distance between the machine zero and work piece zero
can vary. In part program processing this is compensated for by the zero offset.
4.3.4 MACHINE: This operating area is used for Execution of part programs, Manual
control operation of machines. In this operating area we can see the different area of mode
Operating areas, Channel status, Program status, Channel name, Alarm and message line,
Operating mode, Program name of selected program, Channel operational messages,
Channel status display, Additional explanatory text (Help) can be called, Working windows,
NC displays The working windows (program editor) and NC displays (feed rate, tool)
available in the selected operating area are displayed here, Dialog line with Operator
prompts ,Recall function , ETC. function, Horizontal soft keys, Vertical soft keys,. When
press the "Area switchover" key, operating areas are displayed on the horizontal soft key bar
and operating modes are displayed on the vertical soft key bar. By this key to go to the area
menu bar from any location in the menu hierarchy if you wish to select another operating
mode or a different operating area.
P a g e | 25
CNC system have many type of parameters which control the different function of
machine. Tool data, tool compensation, tool management, setting parameters, zero
Offsets-parameter, machine parameter, working area limitation.
Setting Parameter: Setting parameter contains various setting data, Jog data, Spindle
data, Dry run feed rate, Starting angle thread cutting, Zero Offsets, Setting bits, etc.
Setting data are related with jog feed, dry run feed, Spindle max & min. speed, axes
negative & positive limitation etc.
Configuration data decide the no. of axes in CNC machine, which type of drive used
in machine, rating of servo drives. Drive configuration data indicate the power of
servo motor & drives, its current capacity, torque, acceleration, Gain etc. Axis
parameter contains the each individual axis parameter like axis traverse limit in both
direction, type of measuring system, encoder pulse.
Increased Flexibility.
Improved Quality.
Reduced Lead-Time.
Higher Productivity.
Economical Batch Production.
Reduced Cycle-Time.
Reduced Scrap Generation
P a g e | 26
b) Machine parameters
b) Main Dimensions
Tool Height 40 mm 40 mm
Step I Step II
( rpm ) ( rpm )
500 4000
250 2000
125 1000
In the basic Configuration of SINUMERIK 810-M, 1000 (i.e. R00 to R999) parameters are
available in the controller.
5. CAD/CAM System
APPLICATION OF CAD:
The various design related tasks, which are performed by modern CAD system are:
P a g e | 29
1. Geometric modeling
This includes computer compatible mathematical description of the geometry of the
object. This allows the image of the object to be displayed and manipulated on a graphics
terminal through signals.
2. Engineering Analysis
Analysis of the product may involve stress calculations, heat-transfer computations, or
use of differential equation to describe the dynamic behavior of the system being
designed. The computer can be used to aid in this analysis work. Finite element analysis
and mass properties analysis are the two analysis features.
3. Design review and evaluation
It is concerned with the measurement of design against the specification established in the
problem definition phase. The graphics terminal can conveniently accomplish this.
4. Automated drafting
Creation of hard copy of engineering drawings can be done directly using CAD database.
Many drafting package features for automatic dimensioning, scaling of the drawing are
available.
5. Parts classification and coding
CAD database can also be used to develop a parts classification and coding system. This
involves grouping of similar parts based on design and manufacturing aspects.
APPLICATIONS OF CAM:
Application of CAM falls into two broad categories
5.4. G-CODES
G-CODES are preparatory functions, which involves actual tool moves (for example control
of machine). These include rapid moves, feed moves, radial feed moves, dwell, and roughing
and profiling cycles. Most G-codes are modal, means that they remain active until cancelled
by another G-code.
A few of the usual preparatory functions, which are generally present in all machining centers
and are uniformly followed by all controller manufacturers are given below:
5.4.3 DWELL
G04 Dwell
5.4.7 PRESET
G92 Absolute position reference is defined or re-defined
and feed rates are to be used on the part of programmer. It is specified by G01 command,
followed by the end point of the move, and then specified feed rate.
3
Start point
2
1
0
Center End
Shows an arc start point, end point and center point (CW)
Start point
Shows an arc start point, end point and center point (CCW)
Format of G02 and G03 are same except the direction of interpolation.
P a g e | 33
Example: N25 G02 X2 Y0 I0 J-2 (Moves the tool as shown in the first fig.)
N25 G03 X2 Y2 I0 J2 (Moves the tool as shown in the second fig.)
The G71 command defaults the system to metric data unit (millimeters). After encountering
this command all coordinates are adopted as metric (mm) units.
These commands set system to their respective plane as main machining plane for specifying
circular interpolation moves and/or cutter compensation.
P a g e | 35
5.5 M-CODES
M-codes are miscellaneous functions, which are used to control the non-motion related
operations of the cutting machine. M-codes take effect in the sequence in which they are
found.
M00 Program stop
M01 Optional program stop
M02 End of program
M03 Spindle On CW
M04 Spindle On CCW
M05 Spindle stop
M06 Tool Change
M07 Coolant On
M08 Coolant Off
M09 Subroutine end
M30 Program end
Format: N_ M01
The M01 command is an optional stop command and halts program execution only if the
M01 switch is set to ON.
Example: N25 M01
Format: N_M30
The M30 command indicates the end of the program data. It means that there are no more
program commands following it. It is used to end the program and reset it to start.
6.INTRODUCTON TO GEARS:
6.1.DEFINITION OF A GEAR:A toothed machine part, such as a wheel or cylinder,
that meshes with another toothed part to transmit motion or to change speed or direction.
6.2.TYPES OF GEARS:
6.2.1.EXTERNAL VS INTERNAL GEARS
An external gear is one with the teeth formed on the outer surface of a cylinder or cone.
Conversely, an internal gear is one with the teeth formed on the inner surface of a cylinder or
cone. For bevel gears, an internal gear is one with the pitch angle exceeding 90 degrees.
Internal gears do not cause output shaft direction reversal.
6.2.3.HELICAL
Helical or "dry fixed" gears offer a refinement over spur gears. The leading edges of the teeth
are not parallel to the axis of rotation, but are set at an angle. Since the gear is curved, this
angling causes the tooth shape to be a segment of a helix. Helical gears can be meshed
in parallel or crossed orientations. The former refers to when the shafts are parallel to each
other; this is the most common orientation. In the latter, the shafts are non-parallel, and in this
configuration the gears are sometimes known as "skew gears".
6.2.4.BEVEL GEAR
A bevel gear is shaped like a right circular cone with most of its tip cut off. When two bevel
gears mesh, their imaginary vertices must occupy the same point. Their shaft axes also
intersect at this point, forming an arbitrary non-straight angle between the shafts. The angle
between the shafts can be anything except zero or 180 degrees. Bevel gears with equal
numbers of teeth and shaft axes at 90 degrees are called miter gears.
P a g e | 39
6.2.5.WORM GEAR
Worm gears resemble screws. A worm gear is usually meshed with a spur gear or a helical
gear, which is called the gear, wheel, or worm wheel.
Worm-and-gear sets are a simple and compact way to achieve a high torque, low speed gear
ratio. For example, helical gears are normally limited to gear ratios of less than 10:1 while
worm-and-gear sets vary from 10:1 to 500:1.A disadvantage is the potential for considerable
sliding action, leading to low efficiency.
6.2.6.NON-CIRCULAR
Non-circular gears are designed for special purposes. While a regular gear is optimized to
transmit torque to another engaged member with minimum noise and wear and
maximum efficiency, a non-circular gear's main objective might be ratiovariations, axle
displacement oscillations and more. Common applications include textile
machines, potentiometers and continuously variable transmissions.
P a g e | 40
A rack is a toothed bar or rod that can be thought of as a sector gear with an infinitely large
radius of curvature. Torque can be converted to linear force by meshing a rack with a pinion:
the pinion turns; the rack moves in a straight line. Such a mechanism is used in automobiles
to convert the rotation of the steering wheel into the left-to-right motion of the tie rod(s).
Racks also feature in the theory of gear geometry, where, for instance, the tooth shape of an
interchangeable set of gears may be specified for the rack (infinite radius), and the tooth
shapes for gears of particular actual radii are then derived from that. The rack and pinion gear
type is employed in a rack railway.
6.2.8.EPICYCLIC
In epicyclic gearing one or more of the gear axes moves. Examples are sun and planet
gearing (see below) and mechanical differentials.
P a g e | 41
Sun and planet gearing was a method of converting reciprocating motion intorotary
motion in steam engines. It was famously used by James Watt on his early steam engines in
order to get around the patent on the crank.
In the illustration, the sun is yellow, the planet red, the reciprocating arm is blue,
the flywheel is green and the driveshaft is grey.
6.2.10.HARMONIC DRIVE
6.3.GENERAL NOMENCLATURE
Rotational frequency, n
Measured in rotation over time, such as RPM.
Angular frequency, ω
Measured in radians per second. rad/second
Number of teeth, N
How many teeth a gear has, an integer. In the case of worms, it is the number of thread starts
that the worm has.
Gear, wheel
The larger of two interacting gears or a gear on its own.
Pinion
The smaller of two interacting gears.
Path of contact
Path followed by the point of contact between two meshing gear teeth.
P a g e | 43
Pitch surface
In cylindrical gears, cylinder formed by projecting a pitch circle in the axial direction. More
generally, the surface formed by the sum of all the pitch circles as one moves along the axis.
For bevel gears it is a cone.
Angle of action
Angle with vertex at the gear center, one leg on the point where mating teeth first make
contact, the other leg on the point where they disengage.
P a g e | 44
Arc of action
Segment of a pitch circle subtended by the angle of action.
Pressure angle,
The complement of the angle between the direction that the teeth exert force on each other,
and the line joining the centers of the two gears. For involute gears, the teeth always exert
force along the line of action, which, for involute gears, is a straight line; and thus, for
involute gears, the pressure angle is constant.
Outside diameter,
Diameter of the gear, measured from the tops of the teeth.
Root diameter
Diameter of the gear, measured at the base of the tooth.
Addendum, a
Radial distance from the pitch surface to the outermost point of the
tooth.
Dedendum, b
Radial distance from the depth of the tooth trough to the pitch
surface.
Whole depth,
The distance from the top of the tooth to the root; it is equal to addendum plus dedendum or
to working depth plus clearance.
Clearance
Distance between the root circle of a gear and the addendum circle of its mate.
Working depth
Depth of engagement of two gears, that is, the sum of their operating addendums.
Circular pitch, p
Distance from one face of a tooth to the corresponding face of an adjacent tooth on the same
gear, measured along the pitch circle.
Diametral pitch,
Ratio of the number of teeth to the pitch diameter. Could be measured in teeth per inch or
teeth per centimeter.
Base circle
In involute gears, where the tooth profile is the involute of the base circle. The radius of the
base circle is somewhat smaller than that of the pitch circle.
Base pitch, normal pitch,
In involute gears, distance from one face of a tooth to the corresponding face of an adjacent
tooth on the same gear, measured along the base circle.
Interference
Contact between teeth other than at the intended parts of their surfaces.
Interchangeable set
A set of gears, any of which will mate properly with any other.
P a g e | 45
7.1.DESIGN OF A GEAR:
We have been given a crane of capacity 5ton which has to carry loads with angular velocity
of π/3 rad s-1. It is powered by a motor of 3HP.
PHOTO
The pinion gear which is to be designed is to be attached to the end of gear box. This pinion
is meshed with another gear which is coupled to the arm of crane which carries loads.
Assumptions:
Gear ratio=3,
7.1.1.DESIGN CRIETERIA:
𝑇𝑃 = 2𝐴𝑊
1 1
𝐺√1+ +( +2) sin 2∅ −1
𝐺 𝐺
Where,
∅ =Pressure angle
WIDTH OF PINION:
b=2m-4m
PERFORMANCE PARAMETERS
1. First of all design tangential tooth loaded is obtained from the power transmitted and
the pitch line velocity by using the following equations
𝑃
𝑊𝑇 = 𝑉 𝐶𝑉
𝑊𝑇 = Permissble tangential tooth load in N
𝑃 = Power transmitted in W
𝜋𝐷𝑁 𝜋𝑀𝑇𝑁
𝑉 = Pitch line velocity in m/s = = , 𝐷 = 𝑀𝑇
60 60
N = Speed in RPM,
CS= service factor
Type of load Intermittent or 3 8-10 hours per day Continuous 24
hours per day hours per day
Steady 0.8 1.00 1.25
Light shock 1.00 1.25 1.54
Medium shock 1.25 1.54 1.80
Heavy shock 1.54 1.80 2.00
= 𝜎𝑤 𝑏𝜋𝑚𝑦 ,
= 𝜎𝑜 𝐶𝑉 𝑏𝜋𝑚𝑦 , (∴ 𝜎𝑤 = 𝜎𝑜 𝑐𝑣 )
Where,
𝜎𝑤 = Permissible working stress
𝜎𝑜 = Allowable or static stress
𝑦 = Form factor
0.684
𝑦 = 0.124 − , for 1412 ° composite and full depth involute systems
𝑇
0.912
𝑦 = 0.154 − , for 20⁰ full depth involute systems
𝑇
0.841
𝑦 = 0.175 − , for 20⁰ systems
𝑇
𝐶𝑉 = Velocity factor
3 𝑚
𝐶𝑉 = 3+𝑉 , for ordinary cut gear operating at velocities up to 12.5 𝑠
4.5 𝑚
𝐶𝑉 = 4.5+𝑉 , for carefully cut gears operating at velocities up to 12.5 𝑠
6
𝐶𝑉 = 6+𝑉, for very accurate cut and ground metallic gears operating at velocities up to
𝑚
20 𝑠
0.75
𝐶𝑉 = 0.75+√𝑉 , for precision gears cut with high accuracy and operating at velocities
𝑚
up to 20 𝑠
0.75
𝐶𝑉 = 1+𝑉 + 0.25
1
, for non-metallic gears
P a g e | 47
SPINDLE HEAD:
Spindle nose: BT 50
Spindle speed: Variable speed 6000 rpm (max)
Spindle motor: AC spindle motor 11/16 KW (cont. /@50 ED)
Drive to spindle: Thru’ timer belt drive
Spindle taper cleaning: Thru’ pneumatic
TABLE:
Table size: 1250 length × 600 width
T-Slot size: 18mm (5 nos. at 100mm CD)
Max load on table: 1200kgs
X-AXIS:
Stroke: 1050mm
Feed rate: 1-10000mm/min
Rapid transverse: 32000mm/min
Table movement: By AC servomotor thru; ball lead screw and nut (direct drive)
Motor/Torque: 1FK7 101-5AF71/1FG2/18Nm
Guide way: LM Guide way, Make: THK
Ball Screw: Make- Tsubaki
Y-AXIS:
Stroke: 610mm
Feed rate: 1-10000mm/min
Rapid transverse: 32000mm/min
Table movement: By AC servomotor thru; ball lead screw and nut (direct drive)
Motor/Torque: 1FK7 101-5AF71/1FG2/27Nm
Guide way: LM Guide way, Make: THK
Ball Screw: Make- Tsubaki
P a g e | 52
Z-AXIS:
Stroke: 610mm
Feed rate: 1-10000mm/min
Rapid transverse: 32000mm/min
Table movement: By AC servomotor thru; ball lead screw and nut (direct drive)
Motor/Torque: 1FK7 101-5AF71/1FG2/27Nm (with brake)
Guide way: LM Guide way, Make: THK
Ball Screw: Make- Tsubaki
FIXTURE:
Component Loading: Manual
Component Clamping: Manual:
Component Unloading: Manual
CNC SYSTEM:
CNC system: Siemens 802D SL
ADDITIONAL FEATURES:
AC for Electrical Cabinet
Rapid Tapping Facility
Machine Guards as shown
Telescopic covers for LM/guide way protection
Operator pendent (Guar mounted)
Electrical cabinet (Machine mounted)
Manual Pulse Generator
Air compressor
Isolation transformer & Voltage Stabilizer
Linear scale for all three axes part program software
INSTALLATION DATA:
Electrical Main Supply: 415 V AC +/-10%, 3Ph, 50Hz+/-2%
Control Supply: 220V AC for contactors, 24V DC for solenoids
Total Connected Load: 37Kva
Total Floor area: 5580mm×4150mm×3250mm ht.
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Face milling cutter is used for facing operations. Used for removing unnecessary layers on
the job.
P a g e | 56
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Side and end mill cutters are used of prepare holes and grooves. It is used for machining of
job.
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FABRICATION OF GEAR:
As designed above the gear involute profile is prepared in AUTOCAD with designed
dimensions and specifications.
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After the complete preparation of involute gear profile in AUTOCAD, the drawing is saved
and fed to MASTERCAM X for generation of program.
After opening the required gear profile drawing in MASTERCAM X, the necessary
constraints such as tool radius, tool offset, depth of cut, feed rate, zero offset, etc., must be
specified in the software.
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After generation of the program successfully, the program is simulated to check whether it is
free from errors and then fed to the CNC machine.
P a g e | 61
8. CONCLUSION:
CNC machine are used for precision work. The machine will remain operational
and maintain its accuracy for many years, if we are doing proper maintenance as per schedule
and operating the machine with skill. Without having proper operational skill you will not
operate machine. Without doing proper maintenance you may not get required accuracy.