WORKSHOP PROCESSES & MATERIALS 2 WORKSHOP PROJECT 2011

REDUCTION GEARBOX REPORT

UMIT BOSTAN (Erasmus) T00162360

8th December 2011

CONTENTS ;

1. Indroduction

2. Measuring Instruments Used

3. Relevant Calculations

4. Machines and Machining methods used

5. Materials used

6. CNC program

7. Safety practices

8. Conclusion

9. Bibliography

REDUCTION GEARBOX

1. Introduction

A gear box is a device for converting the speed of a shaft from one speed to another. In the process the torque T is also changed. This can be done with pulley and chain drives but gears have advantages over these system. A good example is that of winch in which a motor with a high speed and low torque is geared down to turn the drum at a low speed with a large torque. Similarly, a marine engine may use a reduction gear box to reduce the speed of the engine to that of the propeller. Other examples are motor vehicles, lathes, drills and many more. The diagram shows a typical winch that has a reduction gear box built inside the drum.

This tutorial is not about the design of gears but it should be mentioned that there are many types of gears, each with their own advantages. Here are some examples.

Gears are wheels which mesh with each other through interlocking teeth. Rotation of one wheel produces rotation of the other with no slip between them. The shape of the gear teeth

is important in order to produce a smooth transfer of the motion. The most common shape is the INVOLUTE gear form . The design of the gear teeth also affects the relative position of one gear to another. For example bevelled gears allow the axis of one gear to be inclined to the axis of another. Worm gears convert the motion through 90o and so on. The design also affects the friction present in the transfer. 2. Measuring Instruments Used There are several techniques available to acquire the geometry and dimensions from a part. Hampton chose to perform manual measurements and used photographs to determine the dimensions of the gearbox parts. Greater care was given in measuring dimensions of critical features (I/O shafts, bearing seats). Hampton attempted to perform measurements without dismantling the assembly. Wherever possible engineering experience was combined with empirical measurements for key ways, clearance spaces, and the like. There is a danger of missing important features, because the significance of such features may not be known at the time of measurement. Caliper

A caliper (British spelling also calliper, in technical and formal use a pair of callipers) is a device used to measure the distance between two opposing sides of an object. A caliper can be as simple as a compass with inward or outward-facing points. The tips of the caliper are adjusted to fit across the points to be measured, the caliper is then removed and the distance read by measuring between the tips with a measuring tool, such as a ruler. It is used in many fields such as mechanical engineering, metalworking, woodworking, science and medicine.

Digital caliper

A refinement now popular is the replacement of the analog dial with an electronic digital display on which the reading is displayed as a single value. Some digital calipers can be switched between centimeters or millimeters, and inches. All provide for zeroing the display at any point along the slide, allowing the same sort of differential measurements as with the dial caliper. Digital calipers may contain some sort of "reading hold" feature, allowing the reading of dimensions even in awkward locations where the display cannot be seen. Ordinary 6-in/150-mm digital calipers are made of stainless steel, have a rated accuracy of 0.001 in (0.02mm) and resolution of 0.0005 in (0.01 mm). The same technology is used to make longer 8-in and 12-in calipers; the accuracy for bigger measurements declines to 0.001 in (0.03 mm) for 100-200 mm and 0.0015 in (0.04 mm) for 200-300 mm.

Micrometer A micrometer , sometimes known as a micrometer screw gauge, is a device

incorporating a calibrated screw used widely for precise measurement of small distances in mechanical engineering and machining as well as most mechanical trades, along with other metrological instruments such as dial, vernier, and digital calipers. Micrometers are often, but not always, in the form of calipers.

Architect's scale An architect's scale is a specialized ruler designed to facilitate the drafting and

measuring of architectural drawings, such asfloor plans and orthographic projections. Because the scale of such drawings are often smaller than life-size, an architect's scale features multiple units of length and proportional length increments. For accuracy and longevity, the material used should be dimensionally stable and durable. Scales were traditionally made of wood, but today they are usually made of rigid plastic or aluminium. Architect's scales may be flat, with 4 scales, or have a symmetric 3-lobed cross-section, with 12 scales.

Height gauge A height gauge is a measuring device used either for determining the height of

something, or for repetitious marking of items to be worked on. The former type of height gauge is often used in doctor's surgeries to find the height of people. These measuring tools are used in metalworking or metrology to either set or measure vertical distances; the pointer is sharpened to allow it to act as a scriber and assist in marking out work pieces. They may also be used to measure the height of an object by using the underside of the scriber as the datum. The datum may be permanently fixed or the height gauge may have provision to adjust the scale, this is done by sliding the scale vertically along the body of the height gauge by turning a fine feed screw at the top of the gauge; then with the scriber set to the same level as the base, the scale can be matched to it. This adjustment allows different scribers or probes to be used, as well as adjusting for any errors in a damaged or resharpened probe.

3. Relevant Calculations

MODULE = ADDENDUM

CLEARANCE = 0.25 x MODULE

DEDENDUM = ADDENDUM + CLEARANCE

DEPTH OF CUT = ADDENDUM + DEDENDUM

PITCH CIRCLE DIAMETER(PCD) = MODULE x NUMBER OF TEETH

OUTSIDE DIAMETER = PCD + ( 2x ATTENDUM )

CIRCULAR PITCH =

x PCD / NUMBER OF TEETH

4. Machines and Machining methods used

Milling machine A milling machine is a machine tool used to machine solid materials. Milling

machines are often classed in two basic forms, horizontal and vertical, which refers to the orientation of the main spindle. Both types range in size from small, benchmounted devices to room-sized machines. Unlike a drill press, which holds the workpiece stationary as the drill moves axially to penetrate the material, milling machines also move the workpiece radially against the rotating milling cutter, which cuts on its sides as well as its tip. Workpiece and cutter movement are precisely controlled to less than 0.001 in (0.025 mm), usually by means of precision ground slides and leadscrews or analogous technology. Milling machines may be manually operated, mechanically automated, or digitally automated via computer numerical control (CNC).

Milling machines can perform a vast number of operations, from simple (e.g., slot and keyway cutting, planing, drilling) to complex (e.g., contouring, diesinking). Cutting fluid is often pumped to the cutting site to cool and lubricate the cut and to wash away the resulting swarf.

Vertical mill

In the vertical mill the spindle axis is vertically oriented. Milling cutters are held in the spindle and rotate on its axis. The spindle can generally be extended (or the table can be raised/lowered, giving the same effect), allowing plunge cuts and drilling. There are two subcategories of vertical mills: the bed mill and the turret mill. A turret mill has a stationary spindle and the table is moved both perpendicular and parallel to the spindle axis to accomplish cutting. The most common example of this type is the Bridgeport, described below. Turret mills often have a quill which allows the milling cutter to be raised and lowered in a manner similar to a drill press. This type of machine provides two methods of cutting in the vertical (Z) direction: by raising or lowering the quill, and by moving the knee. In the bed mill, however, the table moves only perpendicular to the spindle's axis, while the spindle itself moves parallel to its own axis. Turret mills are generally considered by some to be more versatile of the two designs. However, turret mills are only practical as long as the machine remains relatively small. As machine size increases, moving the knee up and down requires considerable

effort and it also becomes difficult to reach the quill feed handle (if equipped). Therefore, larger milling machines are usually of the bed type. Also of note is a lighter machine, called a mill-drill. It is quite popular with hobbyists, due to its small size and lower price. A mill-drill is similar to a small drill press but equipped with an X-Y table. These are frequently of lower quality than other types of machines

Horizontal mill

A horizontal mill has the same sort of xy table, but the cutters are mounted on a horizontal arbor (see Arbor milling) across the table. Many horizontal mills also feature a built-in rotary table that allows milling at various angles; this feature is called a universal table. While endmills and the other types of tools available to a vertical mill may be used in a horizontal mill, their real advantage lies in arbor-mounted cutters, called side and face mills, which have a cross section rather like a circular saw, but are generally wider and smaller in diameter. Because the cutters have good support from the arbor and have a larger cross-sectional area than an end mill, quite heavy cuts can be taken enabling rapid material removal rates. These are used to mill grooves and

slots. Plain mills are used to shape flat surfaces. Several cutters may be ganged together on the arbor to mill a complex shape of slots and planes. Special cutters can also cut grooves, bevels, radii, or indeed any section desired. These specialty cutters tend to be expensive. Simplex mills have one spindle, and duplex mills have two. It is also easier to cut gears on a horizontal mill. Some horizontal milling machines are equipped with a power-take-off provision on the table. This allows the table feed to be synchronized to a rotary fixture, enabling the milling of spiral features such as hypoid gears.

Drill Machine There are two types of machine drill, the bench drill and the pillar drill. The

bench drill is used for drilling holes through materials including a range of woods, plastics and metals. It is normally bolted to a bench so that it cannot be pushed over and that larger pieces of material can be drilled safely. The larger version of the machine drill is called the pillar drill. This has a long column which stands on the floor. This can do exactly the same work as the bench drill but because of its larger size it is capable of being used to drill larger pieces of materials and produce larger holes.

Cut Machine An abrasive saw, also known as a cut-off saw or metal chop saw, is a power

tool which is typically used to cut hard materials, such as metals. The cutting action is performed by an abrasive disc, similar to a thin grinding wheel. The saw generally has a built-in vise or other clamping arrangement, and has the cutting wheel and motor mounted on a pivoting arm attached to a fixed base plate. They typically use composite friction disk blades to abrasively cut through the steel. The disks are consumable items as they wear throughout the cut. The abrasive disks for these saws are typically 14 in (360 mm) in diameter and 764 in (2.8 mm) thick. Larger saws use 410 mm (16 in) diameter blades. Disks are available for steel and stainless steel..

CNC Machine Numerical control (NC) refers to the automation of machine tools that are

operated by abstractly programmed commands encoded on a storage medium, as opposed to controlled manually via handwheels or levers, or mechanically automated via cams alone. The first NC machines were built in the 1940s and 1950s, based on existing tools that were modified with motors that moved the controls to follow points fed into the system on punched tape. These early servomechanisms were rapidly augmented with analog and digital computers, creating the modern computer numerical control (CNC) machine tools that have revolutionized the machining processes. In modern CNC systems, end-to-end component design is highly automated using computer-aided design (CAD) and computer-aided manufacturing (CAM) programs. The programs produce a computer file that is interpreted to extract the commands needed to operate a particular machine via a postprocessor, and then loaded into the CNC machines for production. Since any particular component might require the use of a number of different tools-drills, saws, etc., modern machines often combine multiple tools into a single "cell". In other cases, a number of different machines are used with an external controller and human or robotic operators that move the component from machine to machine. In either case, the complex series of steps needed to produce any part is highly automated and produces a part that closely matches the original CAD design.

Machining for Production of Gear Teeth

It appears from the previous section that gears are manufactured in several routes ; The preformed blanks of approximate shape and irregular surface are machined to desired dimensions and finish and then the teeth are produced generally by machining and occasionally by rolling. Full gears with teeth are made by different processes and then finished by further machining and / or grinding Accurate gears in finished form are directly produced by near net shape process like rolling, plastic moulding, powder metallurgy etc. requiring slight or no further finishing.

The most commonly practiced method is preforming the blank by casting, forging etc. followed by pre-machining to prepare the gear blank to desired dimensions and then production of the teeth by machining and further finishing by grinding if necessary. Gear teeth are produced by machining based on Forming where the profile of the teeth are obtained as the replica of the form of the cutting tool (edge); e.g., milling, broaching etc. Generation where the complicated tooth profile are provided by much simpler form cutting tool (edges) through rolling type, tool work motions, e.g., hobbing, gear shaping etc.

Methods of production of gear teeth by machining on Forming principle Shaping, planing and slotting Fig. 7.2.10 schematically shows how teeth of straight toothed spur gear can be produced in shaping machine, if necessary. Both productivity and product quality are very low in this process which therefore, is used, if at all, for making one or few teeth on one or two pieces of gears as and when required for repair and maintenance purpose.

In principle planning and slotting machines work on the same principle. Planing machine is used, if required at all, for making teeth of large gears whereas slotting, generally, for internal gears. Milling

Gear teeth can be produced by both disc and end mill type form milling cutter as shown in Fig. Production of gear teeth by form milling are characterised by : use of HSS form milling cutters use of ordinary milling machines low production rate for need of indexing after machining each tooth gap slow speed and feed low accuracy and surface finish inventory problem due to need of a set of eight cutters for each module pressure angle combination. End mill type cutters are used for teeth of large gears and / or module.

5. Material Used We used the followng materials for gearbox; Aluminium for Housing Aliminium for gear Wheel Aliminium for Worm Aliminium for Hand Wheel Mild Steel for Short Shaft Mild Steel for Long Shaft Mild Steel for M4x4mm Grub Screw The various materials used for gears include a wide variety of cast irons, non ferrous material &non - material materials the selection of the gear material depends upon ; Type of service Peripheral speed Degree of accuracy required Method of manufacture Required dimensions & weight of the drive Allowable stress Shock resistance Wear resistance.

1.Cast iron is popular due to its good wearing properties, excellent machinability & Ease of producing complicated shapes by the casting method. It is suitable where large gears of complicated shapes are needed. 2.Steel is sufficiently strong & highly resistant to wear by abrasion. 3.Cast steel is used where stress on gear is nigh & it is difficult to fabricate the gears. 4.Plain carbon steels find application for industrial gears where high toughness combined with high strength. 5.Alloy steels are used where high tooth strength & low tooth wear

are

required.

6.Aluminum is used where low inertia of rotating mass is desired. 7.Gears made of non - Metallic materials give noiseless operation at high peripheral speeds. 6. CNC Program

The abbreviation CNC stands for computer numerical control, and refers speci cally to a computer controller that reads G-code instructions and drives a machine tool, a powered mechanical device typically used to fabricate components by the selective removal of material. CNC does numerically directed interpolation of a cutting tool in the work envelope of a machine. The operating parameters of the CNC can be altered via software load program. Introduction to CNC There are other codes; the type codes can be thought of like registers in a computer X absolute position Y absolute position Z absolute position A position (rotary around X) B position (rotary around Y) C position (rotary around Z) U Relative axis parallel to X V Relative axis parallel to Y W Relative axis parallel to Z M code (otherwise referred to as a Miscellaneous function) F feed rate S spindle speed N line number R Arc radius or optional word passed to a subprogram/canned cycle

P Dwell time or optional word passed to a subprogram/canned cycle T Tool selection I Arc data X axis J Arc data Y axis. K Arc data Z axis, or optional word passed to a subprogram/canned cycle D Cutter diameter/radius offset H Tool length offset

7. Safety Practices

The vertical mill can be a safe machine, but only if the student is aware of the hazards involved. In the machine shop you must always keep your mind on your work in order to avoid accidents. Distractions should be taken care of before machining is begun. Develop safe working habits in the use of safety glasses, set-ups, and tools. The following rules must be observed when working on the milling machines in the Student Shop: 1. No attempt should be made to operate the mill until you understand the proper procedures for its use and have been checked out on it. 2. Dress appropriately. Remove all watches and jewelry. Safety glasses or goggles area must. 3. Plan out your work thoroughly before starting. 4. Know were the location of the OFF switch is. 5. Be sure the work and holding device are firmly attached to the table. 6. Get help in moving any heavy attachments associated with the mill. 7. Stop the machine before making any adjustments or measurements. 8. Never reach over or near any rotating cutter. 9. Take care to prevent running the cutter into the vice or table. 10. Never leave a machine running unattended. 11. Stop the machine before removing chips, ( remember that chips can be very sharp). 12. Keep the floor around the machine clear of chips. Wipe up spilled cutting fluids immediately. 13. Use a piece of cloth for protection of the cutter and your hands when handling the milling cutters.

8. Conclucion Gearbox plays an important role in power transmission system. It is meant to provide velocity and torque conversions from a rotating power source to another device using gear ratios. It finds its application various machines such as fixed machines, pedal

bicycles, cars and other vehicles, boats and other wherever rotational speed and torque needs to be used.Gearboxes are available in few different types, shapes and size. It could be mechanical as well as automatic. An automatic gearbox, certainly, plays a vital role in many places. In case of cars, the gearbox will usually be associated with the crankshaft of the engine. The output is transmitted through driveshaft to other differentials, which in turn allows the wheel to rotate and push the car forward.It has its application in electric motors as well in wind mill. Here the gearbox is a very important mechanical part. It delivers the power produced by the wind to the electric generator and makes the generator generate the analogous rotating speed. Usually the rotation speed of the wind mill is quite low and does not have the capability to reach the desired speed of the electric generator. Consequently, using a gearbox will be helpful in increasing the efficiency of the machine.The gearbox is usually implemented with the unwavering design. However, it can be customized in accordance to the customer's need. Most of the times the common cases, such as case with parallel axes, rectangular axis, vertical-type or horizontal-type case, are used in the gearbox. If the gearbox is to be used with advanced grinding technology, the circular gear and spiral bevel could prove out to be to best. Amongst all other gears, the Planetary Gear is most important and is commonly used, especially in cars and other vehicles. It's the collection of gears to which the transmission shaft is linked. It usually comprises quite a few separate parts. The outside part of the gear, whose size usually differs for different applications, is meant for building up unique gear ratios. These are the combinations of gears used while the vehicle moves. When the transmission transfers to former, the Planetary Gear begins to move. As soon as the vehicle begins to move,the transmission shift to the second.If the car speed is high ,so is the gear ratio. With the technological advancement, it is very much possible to reduce the temperature and the noise while maintaining the operational consistency. You can find various other gearboxes available such as Helical, Greaves Gearbox etc. which have their relevance in multiple industries like Cement, sugar, Paper and pulp and steel. You can also place order for customized Gearboxes as per the requirements.

9. Bibliograpy

1. 2.

www.wikipedia.org Valeri G. Nesterenko ,Faculty Engines of Aircraft Moscow Avitation Insttute(Engineering Universty) Russia

3.

Mansaf R. Haram, Gearbox Fault Detection using Motor Current Signature

Analysis1stYear PhD

Supervised by Prof. A. Ball and Dr. F.Gu The University of Huddersfield, Queensgate, Huddersfield HD1 3DH, UK 4. A. R. Mohanty and Chinmaya Kar, Fault Detection in a Multistage Gearbox by Demodulation of Motor Current Waveform IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 53, NO. 4, AUGUST 200 5. Neeraj kumar EXPERIMENTAL INVESTIGATION OF FAULTY GEARBOX USING MOTOR CURRENT SIGNATURE ANALYSIS, may 2009. 6. A. R. Mohanty and C. Kar, Gearbox health monitoring through three phase motor current signature analysis, in Proc. 4th Int. Workshop Struct. Health Monitoring, Stanford, CA, 2003, pp. 13661373 7. Z. Lacroix Reusing Mechanical Engineering Design Data in proc. IEEE 3 rd International Conference on information Reuse and Integration, October 2003 to be published by IEEE Press. 8. K. Tombre. Analysis of engineering drawings: State of art and challenges. In Graphics Recognition Algorithms and Systems, volume 1389 of Lecture Notes in Computer Science, pages 257{264, Springer Verlag, April 1998. 9. T. Kanungo, R. M. Haralick, and D. Dori. Understanding engineering drawings: A survey. In Proceedings of First IARP Workshop on Graphics Recognition, pages 217{228, University Park, P.A, 1995. 10. F. Bapst, R. Brugger, A. Zramdini, and R. Ingold. Integrated multi-agent architecture for assisted document recognition. In Document Image Analysis, pages 301{317, World Science, Singapore, 1994. 11. L. Swaminathan. Agent-based engineering drawing analysis. Masters thesis, University of Utah, Salt Lake City, Utah, December 2002. 12. H. Arai and K. Okada. Form processing based on background region analysis. In Proc ICDAR 97, pages 164{169, Ulm, Germany, 1997.