DESIGN AND MANUFACTURE OF SPUR GEAR

A project report submitted

In partial fulfilment of the requirement for the award of the degree of

BACHELOR OF TECHNOLOGY IN
MECHANICAL ENGINEERING
By
A. MOHITH 20071A0305
CHIRANJEEV SAHU 20071A0315
L. SAI PREETH VARMA 20071A0327

Under the guidance of

Dr .M. S. SRINIVASA RAO, Assistant professor

Department of Mechanical Engineering

VNR VIGNANA JYOTHI INSTITUTE OF ENGINEERING &
TECHNOLOGY
(Autonomous)
Vignana Jyothi Nagar, Bachupally, Nizampet (SO), Hyderabad – 500 090
(Approved by AICTE & Govt. of T.S and Affiliated to JNTU, Hyderabad)
November 2023.
 VALLURUPALLI NAGESWARA RAO VIGNANA JYOTHI INSTITUTE OF ENGINEERING
AND TECHNOLOGY

An Autonomous Institute, NAAC Accredited with ‘A++’ Grade NBA Accredited for CE,
EEE, ME, ECE, CSE, EIE, IT B.Tech Courses
Approved by AICTE, New Delhi, Affiliated to JNTUH Recognized as “College with
Potential for Excellence” by UGC
Estd.1995 Vignana Jyothi Nagar, Pragathi Nagar, Nizampet (S.O), Hyderabad – 500 090, TS, India.
Telephone No: 040-2304 2758/59/60, Fax: 040-23042761 E-mail:
[email protected], Website: www.vnrvjiet.ac.in

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that the project report entitled “DESIGN AND MANUFACTURING OF SPUR
GEAR” has been carried out at VNR VJIET, Hyderabad and submitted by the
following Students.
S.No NAME OF THE STUDENT HALL TICKET No.

1. A MOHITH 20071A0305
2. CHIRANJEEV SAHU 20071A0315
3. L. SAI PREETH VARMA 20071A0327

In partial fulfilment of the requirements for the award of the Bachelor of Technology in
Mechanical Engineering to Jawaharlal Nehru Technological University Hyderabad at VNR
Vignana Jyothi Institute of Engineering & Technology during the period of 2020-2024 is a
bonafide of the work carried out by them under the guidance and supervision of the under signed.
The results embodied in this project report have not been submitted to any other University or
institution for the award of any Degree.

T. Malyadri Dr. B. SATYANARAYANA

IOMP Coordinator Head of the Department
Assistant professor Mechanical engineering
VNR VJIET
VNR VJIET
 APPROVAL CERTIFICATE
Viva-Voce examination conducted for the dissertation work entitled “DESIGN AND
MANUFACTURING OF SPUR GEAR” is conducted on……………… and the work is
approved for the award of Degree of Bachelor of Technology in Mechanical Engineering.

INTERNAL EXAMINER EXTERNAL EXAMINER

 DECLARATION

We, the undersigned declare that the project report entitled “DESIGN AND
MANUFACTURE OF SPUR GEAR” has been carried out and submitted in partial fulfilment
of the requirements for the Award of the Bachelor of Technology in Mechanical Engineering
at VNR Vignana Jyothi Institute of Engineering & Technology, affiliated to Jawaharlal Nehru
Technological University, Hyderabad is an authentic work and has not been submitted to any
other university.

PLACE: HYDERABAD A MOHITH (20071A0305)

DATE: CHIRANJEEV SAHU (20071A0315)

L. SAI PREETH VARMA (20071A0327)

 ACKNOWLEDGEMENT

We owe the success of our project to our external guides Mr. Y. Sidda Reddy for his
guidance in completing our project work successfully and for allowing us to do project in his
organization.

We owe a debt of gratitude to our external guide, whose encouragement has been the
principal source of inspiration of this project.

We should like to express our sincere gratitude to our Head of the Department
Dr. B. Satyanaryana for granting us permission to do the project in Excellent Industries and for
continuous encouragement.

Our cordial regards to our respected internal guide & IOMP coordinator Mr. T.
Malyadri, Asst.prof for their encouragement and moral support.

Finally, we express our thanks to all faculty members of the department of

MECHANICAL ENGINEERING

i
 ABSTRACT

The design" Design and Manufacturing of Spur Gear" focuses on the intricate process of
creating perfection- finagled spur gears using advanced manufacturing ways. goad gears
are abecedarian factors in colourful mechanical systems, transmitting power and stir
efficiently.
This exploration trials to ground the gap between theoretical design and practical
perpetration by employing state- of- the- art computer- backed design(CAD) software to
optimize gear figure, icing superior performance, continuity, and reduced noise situations.
The design delves into the complications of gear tooth profiling, pressure angles, and tooth
consistence variations, aiming for optimal gear meshing and cargo distribution. likewise,
the study explores innovative manufacturing methodologies, with a primary emphasis on
advanced milling operations. Employing computer numerical control(CNC) milling
machines, the design investigates the perfection and effectiveness of gear product.

Embracing ultramodern manufacturing practices, similar as cumulative manufacturing

ways, the exploration aims to enhance the product inflexibility and customization of spur
gears. By combining theoretical knowledge, computational simulations, and practical
manufacturing processes, this design strives to deliver precious perceptivity into the design
and manufacturing of spur gears. The findings have wide- ranging counteraccusations for
diligence reliant on precise mechanical factors, promising advancements in gear
technology and contributing to the elaboration of effective, dependable, and high-
performance ministry.

ii
 CONTENTS

TOPIC PAGE.NO

Acknowledgement i

Abstract ii

Contents iii

List of chapters iv

List of figures vii

iii
 CONTENTS
Page no.
List of chapters

CHAPTER-1

INTRODUCTION 1

1.1 Types of gears 1

1.2 Applications 2

1.3 spur gears 2

1.3.1 Advantages 3

CHAPTER-2

LITERATURE REVIEW 4

CHAPTER-3

METHODOLOGY 6

3.1 Material Selection 6

3.2 Design parameters of spur gear 7

3.3 determination of number of teeth- Interference 8

CHAPTER-4

Modelling of spur gear 9

CHAPTER-5

Manufacturing of spur gear 10

CHAPTER-6

Applications 15

CHAPTER-7

Results 17

CHAPTER-8
Conclusion 18

CHAPTER-9

References 19

v
LIST OF FIGURES

Figure no. Description Page

no.
1 Gears 1
2 Types of gears 2
3 Spur gear 3
4 Tooth profile 4
5 CATIA models of spur gear 6
6 Gear blanks 17
7 Gear milling 18
8 Hobbing 19
9 Gear shaping 20
10 Manufactured spur gear 21

vi
 CHAPTER-01
INTRODUCTION

Gears, the modest yet complex mechanical wonders, from the strength of countless
mechanics that drive our modern world. These toothed devices(wheels), with their ability
to transmit power, motion, and torque, are the unsung heroes behind the smooth
functioning of a wide array of devices, from the hands of clock to the most powerful
engines of automobiles. In the realm of machinery, gears play a pivotal role, helping in the
controlled transfer of energy, allowing for varied and precise movements.

Fig1: Gears

Gears are made up of revolving sections with teeth that interlock to transfer mechanical
energy from one area of the machine to another. This is a pretty basic notion. Gears, despite
their basic design, are frequently available in a wide variety of sizes and forms, each
specially designed for a particular use.

1.1 Types of Gears:

Different sized and shaped gears are available, each intended for a particular
purpose. Spur gears, helical gears, bevel gears, and worn gears are the most
prevalent types of gears. Helical gears have inclined teeth that allow for smoother
and quieter operation than spur gears, which are more common in simpler
applications. Bevel gears, which have a cone form and are used to transfer motion
between crossing axes, offer large reduction ratios, making them perfect for
applications that need to significantly reduce speed.

Fig 2: Types of gears

1.2 Applications

A broad spectrum of sectors, including robotics, aerospace, automotive, and

manufacturing, use gears. Gears in the automotive industry provide for smooth speed
transitions, improving performance and efficiency. Within the aerospace industry, they
facilitate accurate movements of aircraft parts, guaranteeing secure and seamless flight
operations. Similar to this, gears are essential to contemporary automated procedures
because they drive the complex motions of robotic arms.

1.3 Spur Gears

Spur gears are the most common and widely used type of gears in mechanical
power transmission systems. They are known for their efficiency, and versatility,
making them essential components in various applications across industries. Spur
gears are characterised by their straight teeth, which are mounted on parallel and
coplanar shafts.

Fig 3: Spur gear

1 DESIGN AND STRUCTURE: Spur gears consists of cylindrical disks with teeth
projecting radially. The teeth are cut parallel to the gear axis, creating straight and
uniform configurations. This design simplifies the manufacturing process and allows
for easy assembly into machinery.

2 MESHING: Spur gears operate by meshing together with other gears to transmit
power and motion. When two gears interlock, the teeth of one gear engage with the
teeth of other, allowing the transfer of rotation energy. The contact between the teeth
ensures a smooth and efficient power transmission.
1.3.1 Advantages

 As spur gears have simple design, making them easier for manufacturing and
assemble.
 Due to their simple design, they are cheaper in terms of manufacturing it in large
numbers.
 Spur gears comparatively have higher efficiencies, meaning they can transmit
powers with minimal energy loss.
 They can be used for both parallel and non-parallel shafts, providing flexibility in
engineering applications.
 CHAPTER-02 LITERATURE REVIEW

 Raunak mahakul et. Al [1]– In this paper they held investigation on design
and numerical analysis of spur considering stainless steel, a composite material
Ti-3Al-8V-6Cr-4Zr (SS) and ZnAC41A alloy as the materials of investigation.
Adopting solid works simulation techniques of the spur gear and numerical
analysis of strain. Stainless steel has comparatively higher resultant pressures
operating on the spur gear, whereas composite materials experience relatively
lower forces. In comparison to the other two materials, the composite material
has a mild stress distribution.
 Pinakanth Dewanji [2] –He worked on the examining an involute spur gear
tooth's bending stress properties under static load circumstances. The tooth
profile was created with CATIA V5, and ANSYS software was used for the
finite element analysis. This work uses current theoretical models to
analytically assess the stresses at the tooth root. The gear tooth root area
experiences the highest pressures, according to the findings. Therefore, the
FEM model suffices for taking dynamic stress into account.
 K. Srinivas et. Al [3] –In this project spur gear it is loaded into ANSYS for
modal and static structural analysis after being modelled in SOLIDWORKS.
The von-mises stresses and deformation are calculated using a static analysis
method. The natural frequencies and mode shapes are found via modal
analysis. Lewis equation theoretical computations were used to validate the
results. Different gear materials, such as epoxy E glass UD, structural steel,
grey cast iron, and aluminium alloy, are taken into consideration during
analysis, and the outcomes are compared. They conclude by saying that, when
compared to structural steel, grey cast iron, and aluminium alloy, the stress
values computed by the composite materials are close to the same.
 Mahendran, S., K. M. Eazhil, et Al [4]. "Design and analysis of composite
spur gear." In an effort to examine weight reduction and stress distribution for
cast iron and composite materials, the researchers manufactured spur gears in
this publication. Based on their investigation, they found that the stress values
for composite materials were lower than those for cast steel spur gears.
According to these analyses, gearboxes made of composite materials may be
used in cars with a maximum load capacity of 1.5 KN.
 MV Jagannadha Raju et. Al [5] "Design and analysis of spur gear
manufactured by DMLS process." In this study, complex mechanical
components like spur gears have been manufactured using sophisticated
production techniques including direct metal laser sintering. Solidworks
software is used to produce 3D modelling while taking the spur gear's design
characteristics into account. Calculations using the Lewis and Caciliano
equations yield the design parameters. Production times will be shortened by
3D printed components, which also enable the fabrication of intricate designs
without the expense of moulding. The idea of advanced manufacturing may be
used in the production of various mechanical parts, such as composite material
moulds, tooling dies, propellers, and gears.
 CHAPTER-03 WORK METHODOLOGY

3.1 MATERIAL SELECTION

 Polymer Materials
Plastic spur gears are composed of an array of plastics, including nylon,
polyethylene (UPE), polyacetal (POM), and ketone polymers. Plastic spur
gears can operate without creating friction, are inexpensive to make,
lightweight, and resistant to corrosion. They are extensively utilized in the
manufacturing of toys, medical equipment, electronics, and food.

 Polyoxygen (POM)
Spur gears are often made of POM, an extremely robust plastic. It is readily
made, molded, and shaped. POM is incredibly rigid, robust, and abrasion-
resistant once it solidifies. Spur gear manufacturers finds POM to be an
appropriate material due to its durability and malleability.

 CAST IRON
Like POM, cast iron is resistant to corrosion and can be shaped into any shape.
Different elements are used in the composition of cast iron, each of which
contributes to the material's unique strength and durability. Because of its low
cost, resistance to corrosion, and ease of molding and shaping, cast iron is
frequently used to make machine components. Depending on the types of extra
combinations applied, it might be incredibly strong or extremely fragile.

 Spur Gear Steel

An alloy of iron, carbon, and other elements is called steel. Tool steel, alloy,
carbon, and stainless steel are the four main categories of steel. Because it is
readily accessible, affordable, wear-resistant, and easy to produce, carbon steel
is the most commonly utilized material to make spur gears.
There are three types of carbon steel: mild, medium, and high carbon. Mild
carbon steel has a carbon content of less than 0.3%. Spur gears shall be made
from any of such types of steel.
Carbon steel may be made as hard as 55 on the Rockwell Hardness scale by
either induction hardening or laser hardening. When other alloys are added to
carbon steel, it becomes more robust, machine-friendly, and produces a
resistance to corrosion. Spur gears are made of all varieties of alloyed carbon
steel.
3.2 Design Parameters of Spur gear

 Dimension Specifications:
Teeth with extremely precise geometry are used to join gears. There
are several methods to represent pitch, which is a measurement of tooth
spacing.
Diametral pitch (DP) is the ratio of the number of teeth to the pitch diameter of a gear; a
higher DP therefore indicates finer tooth spacing. It is easily calculated by the formula
DP= (N+2) / OD, where N is the number of teeth, and OD represents the circumferential
measurement.
Circular pitch (CP) is a direct measurement of the distance from one tooth centre to the
adjacent tooth centre. It can be measured by the formula CP= 𝝅/DP
Module (M) is a typical gear discipline and is a measurement of the size teeth number of
the gear. Gears measured in inches earn 'English module' distinction to prevent confusion.
M = OD/N
Pressure angle is the angle of tooth drive action, or the angle between the line of force
and between meshing teeth and the tangent to the pitch circle at the point of mesh. Typical
pressure angles are 14.5° to 20°.

Fig 4: Tooth profile

3.3 Determination of Number of Teeth – Interference
Here, we'll learn how to calculate the total number of teeth on each gear. We must assume
the tooth count of one gear (T1), let's say the smaller gear, in order to perform this. We
may now calculate the number of teeth on the other gear, T2 , using the relation shown
below.
T2=(T1/Dp1)* Dp2
Lewis Equation: Design for Mechanical Strength
The breadth of the gear teeth, b, is the fundamental design parameter that is still present.
This is ascertained by determining if the maximum bending stress at the root of the gear,
Ft, caused by the tangential component of the transmitted load, is larger than the
permissible stress. The power transmitted (P) and pitch line velocity (V) of the gear Ft may
be found using the relation that follows.
Ft V= Transmitted Power
 CHAPTER-04 MODELLING
OF SPUR GEAR

The multi-platform commercial CAD/CAM/CAE software suite CATIA (Computer Aided

Three-dimensional Interactive Application) was developed by the French Firm Assault
Systems. CATIA is the primary element of the Assault Systems lifecycle management for
products software package, and it is written in the C++ programming language.
In the CAD/CAM/CAE market, Solid Edge, Siemens NX, Pro/E, Autodesk Inventor, and
many more products are competitors of CATIA.

Fig 5: CATIA models of spur gear

 CHAPTER-05 MANUFACTURING OF SPUR GEAR

Spur gears are produced using a variety of techniques, including forging, CNC
manufacturing, blank machining, casting, grease paint metallurgy, and cutting.
Whichever method is employed, the least amount of mistakes can aid in the
correct meshing of gears, thus dimensional precision and adherence to
forbearance are crucial. Goad gears are forged, cut, or machined when
extraordinary performance is required.

 Manufacturing of Spur gears

Gear Blanks: The slicing process starts, in any case, with a gear blank. The kind
of material used for producing the gear blank affects the spur gear's quality. Pie-
shaped billets are the sole high-quality component that can be used to create spur
gears with superior quality.

Fig 6: Gear blanks

Milling Procedure: In milling operation, to cut the tooth gap, a form cutter on a
milling machine is used to pass through the gear blank. The workpiece is
positioned during form milling so that the cutter may go perpendicularly along
the tooth's axial length at the appropriate depth. The gear blank turns for the
subsequent cut once the cutter is withdrawn at the conclusion of each cut. The
cutter is shaped like the interproximal gap in teeth.

Fig 7 : Gear milling

Hobbing Process The hobbing process involves the simultaneous, perpetual

motion of the gear blank and the hob, allowing them to mesh while the teeth are
cut. The hob, or tool, is fed inward until its cutting blades are evenly spaced and
it reaches the correct depth. Hobbing is a quick and precise procedure. The hob
cuts horizontally while the gear blank revolves on its vertical axis. To make the
gear, each tooth's facets are cut to resemble the hob's gashes, resulting in a
significantly more accurate tolerance and profile.

Fig8: Hobbing
Gear Shaping Internal spur gears may be made using the gear shaping technique,
which makes use of a cutting tool consisting of a gear with cutting edges that
rotates axially against the workpiece's inner diameter. The cutting gear and the
gear that is being produced revolve at the same velocity ratio. Until the gear teeth
are at the correct depth, the cutting tool motion is repeated several times. The
workpiece and tool are rotated during the gradual process while the tool keeps
oscillating.
All of the many types of spur gears with excellent internal and exterior surface
finishes may be produced by gear shaping. The shaping tool resembles a rack-
type gear or a cylindrical gear.

Fig9 : Gear shaping

 Advantages of using milling operation for manufacturing milling process:

Precision Milling operations allow for precise control over the confines and
forbearance of the gear teeth, performing in high- quality gears with accurate tooth
biographies. Customization Milling can be used to produce spur gears with specific
tooth biographies, tooth figures, and pressure angles to meet the conditions of a
particular operation.

Cost- effectiveness Milling is a cost-effective system for producing spur gears,

especially for small to medium product runs. It can be more provident than other
styles like gear shaping or hobbing for low to moderate amounts.

Versatility Milling machines can be acclimated to produce a wide range of gear

sizes and types, making them suitable for colourful gear operations. Batch product
Milling is well- suited for batch product, making it ideal for manufacturing spur
gears in large amounts.
Tooling inflexibility Milling knives can be fluently changed to accommodate
different gear sizes and tooth biographies, allowing for inflexibility in product.
Reduced setup time ultramodern CNC milling machines and software can
significantly reduce setup time, adding overall effectiveness. High material
application Milling is effective in terms of material application, as it generates lower
waste compared to some other gear manufacturing style.
 CHAPTER-06 APPLICATIONS

The most popular type of gear, spur gears are used in many different applications.
Among the many vital tasks they carry out, supplying gear reduction to
mechanically motorized equipment is among the most crucial. A spur gear meshes
flawlessly with other gears after it is installed on a parallel shaft.

Spur gears are straightforward to mount with ball bearings since their teeth are
parallel to the rotational axis and do not create axial thrust. These are reasonably
priced, precisely designed, and simple to use and install goods.

Varying Velocity

Spur gears are the perfect choice for applications where speed increases or
decreases. They transmit power and motion from one shaft to another, allowing for
precise control of positioning systems as well as changes in the speed at which
machinery operates. They are used in clocks to change the pace of the minute, hour,
and second hands for this purpose.

Cleaning Equipment

Spur gears are used in washing machines to control the rotating motion of the
machine as they regulate the pace of applications. Spur gears help to increase or
decrease torque depending on the cycle that the machine is running.

Automotive Industry

Spur gears, particularly in manual gearboxes, are extensively utilised in cars to

provide functions like steering and braking adjustments.

Manufacturing machines

Printing presses, conveyor systems, and packing machines are just a few of the
applications for spur gears in manufacturing machinery.

Power Tools

In order to transfer power from the engine to the cutting or drilling mechanism,
spur gears are utilized in power tools such as drills and saws.
Mechanical Watches and Clocks

Pinch gears are employed in clock mechanisms to regulate hand motion and
guarantee precise timekeeping.

Robotics

For accurate movement and control of robotic arms and other moving elements,
spur gears are used in a variety of robotic applications.

Aerospace Industries

Spur gears are used in landing gear systems and other mechanical parts of
aeroplanes and spacecraft in the aerospace industry.

Marine Industry

Propeller speed and direction adjustments are among the many jobs that spur gears
are employed for in boats and ships.

Railway Industry

In trains, spur gears are used to regulate different mechanical systems and to change
the locomotive's speed and di
 CHAPTER- 07 RESULTS

By design and manufacturing using milling operation we obtained desired spur gear
with required dimensions’ parameters

Fig10 : Manufactured spur gear

 CHAPTER- 08
CONCLUSION

A spur gear is a cylindrical toothed gear that runs parallel to the shaft. It is used for
controlling torque, power, and speed between shafts in addition to transmitting mechanical
motion.

A spur gear’s design, construction, and materials affect its performance. The fabrication
process, which uses premium materials and stringent dimensional compliance to ascertain
a spur gear's performance, is a crucial component in the creation of a spur gear.

Spur gears are made using a number of techniques, including computer numerically
controlled production, powder metallurgy, forging, cutting, blank machining, and casting.
No matter the procedure, dimensional precision and tolerance observance are essential
since even the smallest mistake might cause the gears to not mesh well. Spur gears are
machined, cut, or forged when extraordinary performance is needed. In this we studied the
process of manufacturing of pur gear my milling and other few operations.

Spur gears may be made from almost any material used to build other items, including
titanium, steel, brass, plastics, alloys of aluminum, and grades of stainless steel. Hardened
steel is the most often utilized option because of its precision in preventing early wear.
 REFERENCES

 Dewanji, Pinaknath. "Design and analysis of spur gear." International Journal of

Mechanical Engineering and Technology (IJMET) 7, no. 5 (2016): 209-220.

 Mahakul, Rounak, Dhirendra Nath Thatoi, Sasanka Choudhury, and Pragyan

Patnaik. "Design and numerical analysis of spur gear using SolidWorks simulation
technique." Materials Today: Proceedings 41 (2021): 340-346.

 Mahendran, S., K. M. Eazhil, and L. Senthil Kumar. "Design and analysis of

composite spur gear." International Journal of Research and Scientific
Innovation 1, no. 6 (2014): 42-53

 Osakue, Edward E., and Lucky Anetor. "Spur gear design: Some new
perspectives." International Journal of Research in Engineering and
Technology 5, no. 9 (2016): 275-286.

 Keerthi, M., K. Sandya, and K. Srinivas. "Static & dynamic analysis of spur gear
using different materials." International Research Journal of Engineering and
Technology (IRJET) 3, no. 01 (2016): 2395-0056.