Project report

Manufacturing Process and Design Of Machine

Elements
Gear Box

Group 1
Nishith Patel-1643010
Bhautik Patel-1643015
Dhavlesh Suthar-1643024
 Acknowledgment

We would like to express out sincerest gratitude to Ahmedabad University

for giving us this opportunity to work collectively for this project.

We would like to express our special thanks of gratitude to our guide V.R.
Iyer who gave us golden opportunity to do this project of Gear Box.

We would also like to thank Bhavin sir and Sanket sir for their support and
guidance during our project. We would also like to thank people who
directly or indirectly guided us for the project

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 Aim

To design and develop a Gear Box

Objective

To reduce the speed of the gear to 1/9 times the input speed using a gear
train.

Introduction

A transmission is a machine in a power transmission system, which provides

controlled application of the power. Often the term transmission refers
simply to the gearbox uses gear and gear trains to provide speed and torque
conversions from a rotating power source to another device.
Often, a transmission has multiple gear ratios (or simply "gears") with the
ability to switch between them as speed varies. This switching may be done
manually (by the operator) or automatically. Directional (forward and
reverse) control may also be provided. Single-ratio transmissions also exist,
which simply change the speed and torque (and sometimes direction) of
motor output.

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Types of Gears:
1) Spur Gear/Parallel Axes
2) Miter Gear/Intersecting Axes
3) Screw Gear/Nonintersecting Axes
4) Helical Gear
5) Gear Rack
6) Bevel Gear
7) Spiral Bevel Gear
8) Worm Gear
9) Internal Gear

Spur Gears

Spur gears are the most easily visualized common gears that transmit motion
between two parallel shafts. Because of their shape, they are classified as a
type of cylindrical gears. Since the tooth surfaces of the gears are parallel to
the axes of the mounted shafts, there is no thrust force generated in the axial
direction. Also, because of the ease of production, these gears can be made
to a high degree of precision. On the other hand, spur gears have a
disadvantage in that they easily make noise. Generally speaking, when two
spur gears are in mesh, the gear with more teeth is called the “gear” and the
one with the smaller number of teeth is called the “pinion”.

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The unit to indicate the sizes of spur gears is commonly stated, as specified
by ISO, to be “module”. In recent years, it is usual to set the pressure angle
to 20 degrees. In commercial machinery, it is most common to use a portion
of an involute curve as the tooth profile.

Even though not limited to spur gears, profile shifted gears are used when it
is necessary to adjust the center distance slightly or to strengthen the gear
teeth. They are produced by adjusting the distance between the gear cutting
tool called the hobbing tool and the gear in the production stage. When the
shift is positive, the bending strength of the gear increases, while a negative
shift slightly reduces the center distance. The backlash is the play between
the teeth when two gears are meshed and is needed for the smooth rotation
of gears. When the backlash is too large, it leads to increased vibration and
noise while the backlash that is too small leads to tooth failure due to the
lack of lubrication.

Stub Tooth

The gears in the system have shorter addendum and shorter dedendum. The
interfering portion of the tooth, that is a part of addendum is thus removed.
Therefore, these teeth have still smaller interference. This also, reduces the
undercutting. In this system, the minimum number of teeth
on pinion to avoid interference is 14. Since the pinion is small, the drive
becomes more compact. Stub teeth are stronger than full depth teeth because
of smaller moment arm of bending force. Therefore, stub system transmits

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very high load. Stub teeth results in lower production cost, as less metal
must be cut away. The main drawback of this system is that the contact
ratio is reduced due to short addendum. Due to insufficient overlap,
vibrations are likely to occur.

Backlash

Backlash is defined as the amount by which the width of tooth space exceeds
the thickness of the engaging tooth measured along the itch circle.IN
general, backlash is the play between mating teeth and it occurs only when
teeth are in mesh.

Backlash prevents the mating teeth from jamming together. The mating
teeth do not make contact on both sides simultaneously. This make the
teeth roll together freely and smoothly. Backlash compensates for
machining errors. Backlash compensates for thermal expansion of teeth.

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 Approach

The main approach of choosing the material was to choose the kind of gears
for the Gear Box. The material chosen for gears were cast iron. After
choosing the gears material, then we chosen main body (structure) material
which was mild steel.

Reason for choosing mild steel:

 Low cost
 Good enough strength
 Easily available
 Good Machinability
 High ductility

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 Design Calculations

FOR SHAFT

 Material – C40
 N (Speed of motor) =1440 rpm
 T (Yield strength of C40) =600 MPa
 F. S=4
 Shaft has keyway (so, value is reduced 25%)
 τ (Shear stress of C40) = (0.3) (0.75) (600)
 τ =135 MPa
𝟏𝟑𝟓
 τ= =33.75MPa
𝟒
2πNT
 P (Power of motor) =
60

 T (Torsion) =9.899 N-m

𝜋𝑑^3𝝉
 T=
𝟏𝟔

 d (Diameter of Shaft) =16.7 mm ≈18mm (From R20 Series)

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Fatigue Failure of Shaft

 Sut (Ultimate stress of C40) = 841 MPa

 Se’ (Endurance limit) = (0.4) Sut
 Se (Endurance limit) = Ka Kb Kc Kd Ke Kf Se’
 Se = (0.821)(1)(0.85)(1)(1)(1)(336.4)
 Se = 234.75 MPa
234.75
 Se= =58.689 MPa
4

For Keyways

 b (width) = 6mm
 h (depth) = 6mm
 l (length) = 45mm
 F = T/r =1099.88N
F 1099.88
 σ c (Compressive stress) = = (45)(2.8) = 8.72MPa
A

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 For Bearing
 ID (Inner Diameter) = 20mm
 OD (Outer Diameter) = 32mm

 b (width) = 7mm
 C (dynamic load) = 2700N
 𝐶0 (Static load) = 1500N
𝐶
 Life of Bearing 𝐿𝑛 = ( )3
𝐶0

 Life of bearing in hours 𝐿ℎ = 5.832*106 / 720*60 = 135hours

For pulley and belt

 𝐷𝐵 = 70 mm
 𝐷𝐴 = 140 mm
 L = 600 mm
 𝑁 = 1440 𝑟𝑝𝑚
𝛑𝐷 N
 V1(Speed of pulley) = (𝟔𝟎)(𝟏𝟎𝟎𝟎)
𝐵
=5.27m/s

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 𝐷𝐵
 θA= 180°-2sin-1(𝐷𝐴 − ) =173.31° =3.023 rad
2𝐶

 Arc of contact connection factor = 1.05

 Service load factor = 1.2
 Rated power = (1.492) (1.05) (1.2)
= 1.879 KW

(0.0118)(5.27)
 Corrected load rating at 5.27 m/s speed = =0.01243
5

KW/ply/mm
 We choose 4- ply belt (0.01243) (4)(b) = 1.879
 b(width)=37.79mm
 b ≈ 40 mm
 θA= 3.023 rad

 θB = 3.257 rad
 DA= 0.07 m

DB= 0.14 m
θA∗ DA θB∗ DB
 L = (4L2-(DB-DA)2)1/2 + + =1.53 m
2 2

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 For Gears (CI Material)
 We selected 4 spur gears in gear train.

Gear No. Diameter(mm) Teeth of gear

1 40 40
2 120 120
3 50 50
4 150 150

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  For Gear 1 and 2
No. Item Symbol Formula Example
Pinion Gear
(1) (2)
1 Module m 1
2 Reference Pressure α 20°
Angle
3 Gear Ratio i 3
4 Center Distance (mm) a m(𝑧1 +𝑧2 )/2 80
5 Height Factor 𝑓𝑜 1
6 Bottom Clearance c 0.25*m 0.25
7 Number of Teeth z (2a)/(m(i+1)) 40 120
8 Addendum (mm) ha 1(m) 1 1
9 Dedendum (mm) hf 1.25(m) 1.25 1.25
10 Reference Diameter d zm 40 120
(Pitch Diameter) (mm)
11 Base Diameter (mm) 𝑑𝑏 dcosα 37.58 112.75
12 Tooth Depth (mm) h 2.25m 2.25 2.25
13 Tip Diameter (mm) 𝑑𝑎 (z+2*𝑓𝑜 ) ∗ 𝑚 42 122

14 Root Diameter (mm) 𝑑𝑓 (z-2*𝑓𝑜 ) ∗ 𝑚 − 37.5 117.5

2∗𝑐

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  For Gear 3 and 4
No. Item Symbol Formula Example
Pinion Gear
(1) (2)
1 Module m 1
2 Reference Pressure α 20°
Angle
3 Gear Ratio i 3
4 Center Distance (mm) a m(𝑧1 +𝑧2 )/2 100
5 Height Factor 𝑓𝑜 1
6 Bottom Clearance c 0.25*m 0.25
7 Number of Teeth z (2a)/(m(i+1)) 50 150
8 Addendum (mm) ha 1(m) 1 1
9 Dedendum (mm) hf 1.25(m) 1.25 1.25
10 Reference Diameter d Zm 50 150
(Pitch Diameter) (mm)
11 Base Diameter (mm) 𝑑𝑏 dcosα 46.98 140.94
12 Tooth Depth (mm) h 2.25m 2.25 2.25
13 Tip Diameter (mm) 𝑑𝑎 (z+2*𝑓𝑜 ) ∗ 𝑚 52 152

14 Root Diameter (mm) 𝑑𝑓 (z-2*𝑓𝑜 ) ∗ 𝑚 − 47.5 147.5

2∗𝑐

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 Allowable Errors
Gear 1 Gear 2 Gear 3 Gear 4
𝑓𝑡 , 𝑓𝑒 , 𝑓𝑓 5 7 5 7
𝐹𝑡 18 25 18 25
𝑓𝑟 16 20 16 20
(All dimensions are in microns)

𝑓𝑓 = involute profile error

𝑓𝑒 = 𝑏𝑎𝑠𝑒 𝑝𝑖𝑡𝑐ℎ 𝑒𝑟𝑟𝑜𝑟
𝑓𝑡 = 𝑒𝑟𝑟𝑜𝑟 𝑖𝑛 𝑎𝑑𝑗𝑎𝑐𝑒𝑛𝑡𝑝𝑖𝑡𝑐ℎ𝑒𝑠
𝐹𝑡 = cumulative pitch error
𝑓𝑟 = radial run out

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 Gear 1
Shaft

Bearing

MS
Plate

Gear 2

Gear 3
Gear 4

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 Parts that were modeled according to the ergonomics, hammer height, space
available and availability of dimension are listed below with their
dimension:

No. Material Quantity Length, Width, Diameter

Height
1 MS Plate 2 300mm*200mm*6mm
2 Bolts 4 6in 5mm
3 Nuts 12 5mm
4 Wiser 16 5mm
5 Bearing 6 ID=19mm,OD=60mm
housing
6 Shafts 2 190mm 19mm
1 130mm 19mm
7 Gears 1 10mm 40
1 10mm 120
1 10mm 50
1 10mm 150
8 Keyways 2 30mm*6mm*6mm
1 80mm*60mm*60mm
9 Bearings (No. 6 8mm 19mm
6204)

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 Fabrication Chart
Took plate of
MS Plate required
dimensions
Made holes
for shafts

Gears Casted block

Did
machining
Made teeth by
hobbing

Took bearings Made bearing

Bearings of required
dimensions
houses for
fitting

Did turning
Shafts for required
diameter
Tapered

Keyways Made
keyways
Made slots in
shafts

Fabrication
 Firstly, we did the calculation part using data book and use of other
material. After that we made solid works design. After done the all
the design and calculation part.
 Now, we grew threw a manufacturing part. So, in manufacturing part
firstly we made all the gears by casting because according to the
calculation gears were not available in market.
 So, in casting the noted our dimensions then they made a pattern of
gears and after that they pouring cast iron material then they finished
the gears.

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 After that all the material came, we did first of all drilling in MS plate
using 19mm drill bit on pillar drilling machine which was done by us.
 We did also boring part for housing to fit bearings.
 Then we took all three shafts of 190mm length and did tapering,
turning, surfacing, processes on shaft which was also done by us.
 Then we did teeth on the Hobbing machine with the module of 1.
 Then we came to the bearing part so, for this gear box we didn’t have
this perfect dimension of bearings were not available in the market so
we did bearing housing on the Circular Rod. and then we fitted
bearings on bearing housing.
 Then we put some 3mm gap on gears and shaft for the keyway.
 After all the parts work was done.
 Now we came to build up part. For build up(assembly) part first of all
we drill 18 holes using drilling machine on MS plate for bearings then
we fitted 6 bearings into housing.
 Then we did threading on bearing housing for fittings of Ln screw
which was done by us.
 Then we fitted shaft into 6 bearings but somehow, we didn’t did
perfectly tapered on to 3 shafts. So, shafts didn’t grew through
perfectly into the holes. So, we did this part very accurately in lath.
 After that shaft grew through into the holes. We set gears and shaft
using keyway.

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 Then we matched the gear’s teeth then we fit ln screw on the gears.
 After all the shafts, gears were fit. We tight four bolt surrounding gear
box.

Assembly

Aligned
Gears
Put shaft
with
keyways
Fitted and gears
bearing
with
MS Plate bearing
houses in
plate

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 Alterations in Design

 Due to budget we chose cast iron gear instead of cast steel gear. If we
chose cast steel gear then gear life and gear hardness will increase
instead of cast iron. also, Smoothness of Gear Box will increased.
 If we chose helical gear instead of spur gear then Machine can be
absorbed higher load.
 For this particular design we developed for high torque but if we
changed the position of 1st and 2nd Gear as well as 3rd and 4th Gear
then we got low torque and high speed. This Particular scenario also
will do if we need high speed.

Observation
 We thought for using cast steel for manufacturing of gears but due to budget
constrains used cast iron for gears.
 Due to slight misalignment of holes bearing was locked. By lubricating we
solved that.
 Because of using of spur gear faced noise while rotating

Result
 As per the objective speed reduced 9 times of input.

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 Applications

 All kind of mechanical transmission system

 Wind turbine
 Mostly in industrial applications where an approximate total gear ratio
between 5:1–12:1 is desired.

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