design of spur gear

7/26/2019 Design of Spur Gear

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DEVELOPMENT OF LIGHT

WEIGHT COMPOSITE GEARSFOR AUTOMOBILE

PRESENTED BY

JAGADISHKUMAR K

KOUSHIK S V

SIBI VISHVAK S

ANBARASAN C M


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Automobile industries, the major contributor to worlds

economy have been continually putting efforts to reduce

the weight of the automobile.

An automobile is a combination of many subsystems and

each and every subsystem contributes to the weight of an

automobile.

The choice of a gear material depends on four factors:

o Mechanical properties

o Metallurgical characteristics

o lan! preparation

o Manufacturing process


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Aluminium

" most environmental friendly

" material of choice" weighs one"third of steel

A comparison between high alloy steel #$ %&% and aluminium '('&

PROPERTIES STEEL EN 353 ALUMINIUM 7075

)ensity *!g+ -%(( -/(

0o"efficient of Thermal

e1pansion *

2.34 %.54

6oungs modulus*78a /2% '/.'

Tensile strength *M8a 3-2.& &'

PROPERTIES STEEL EN 353 ALUMINIUM 7075

-%(( -/(

2.34 %.54

6oungs modulus*78a /2% '/.'

Tensile strength *M8a 3-2.& &'


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89;#M )#uirements.

Major draw bac! is its weight.


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?#0T=@#

)evelop an alternate material for transmissiongears.

9educing weight.

To test the gears for re>uired tor>uetransmission and power.


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M#T);76

PROBLEMDEFINITION

LITERATURESURVEY

FEASIBILITYSTUDY

DESIGN

CALCULATION

CNTPRODUCTION

CNTCHARACTERISATI

ON

GEARFABRICATION

GEAR TESTING


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)#B=7$ < B8C9 7#A9Maruti Suzuki Alto 800 specifcation

PARAMETER VALUES

Maximum Power 4 !"#

Maximum Tor$ue %& Nm

Fir'( Gear )i* +,-

Se.o/0 Gear )i* 1,23

T"ir0 Gear)i* 2,++

Four(" Gear)i* &,&


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i D 7ear ratio E " eli1 angle

D #ngine Tor>ue D Ma1imum tor>ue

D #ngine speed D $umber of teeth on pinionD Module " $umber of teeth on gear

a D 0entre distance # D #>uivalent 6oungs modulus

D


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ending strengthm 62,13

m m 7 2,11Pre8erre0 mo0u9e m 7 +

CHECKING OF BENDING STRENGTH

7 :

7

7 2+3 ; -%1


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0ontact strengtha G *iH/

a G *.53 4

a G 3/.' mm

CHECKING OF CONTACT STENGTH

7 :

7 :

7 31,+ ; 3+&


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7ear dimensions

!AAMETES "A#$EMo%ule +Centre %istance 3 mm

Hei&'t (actor 2Toot' %ept' &,%- mm

!itc' %ia)eter

*!inion+ 224 mm

!itc' %ia)eter

*Gear+% mm

Tip %ia)eter

*!inion+21& mm

Tip %ia)eter

*Gear+4 mm

oot %ia)eter

*!inion+2&3,- mm

oot %ia)eter

*Gear+ %&,- mm


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0arbon nano tubes

" (u!e


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Hexa>o/a9 '"ee( o8 >ra#"e/e mo0e9 o8 )a* a/arm."air /a/o (u!e

)!* a i> /a/o(u!e a/0 ).* a ."ira9/a/o (u!e

arm."air )/ /* ."ira9 8or )/ m* i>a> 8or )/ &*


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#lectrodes

Cath!" #$% && ' (00 &&

A)!" I3 mm J (( mm

.a("o0e a/o0e


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8roduction of 0$T

8reparation of electrode


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8ressure set"up


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loc! diagram of )0 arc discharge method


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Trials

TRIALS CATALYST VOLTAGE*V+

PRESSU

RE*,-./&

+

WEIGHT*-+

$


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9T#M 0haracteriation

0arbon coated cathode grip 9T#M ?#; ?#M /((


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Trial"/CATALYST F"1N2*005 -+

VOLTAGE 2( @

PRESSURE "(.% !g+cmN

9T#M image and electro diffraction pattern of trial"/


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Trial"CATALYST F"

VOLTAGE 2( @

PRESSURE "(.5 !g+cmN

HRTEM ima>e a/0 E9e.(ro 0ira.(io/ #a((er/ o8 (ria9


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Trial"%CATALYST F"44/")"

VOLTAGE 2( @

PRESSURE "(.& !g+cmN

HRTEM ima>e a/0 E9e.(ro/ 0ira.(io/ #a((er/ o8 (ria9


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7ravity casting

*a 7ear

*b die component*c furnace


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B>ueee casting

*a 7ear with bro!en die

*b accurate gear profile

*c hydraulic press


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obbing process

*a Melting of Al"'('& pieces

*b 0$T powder

*c 7ear blan!s


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*a 7ear of (. O of 0$T

*b 7ear of (.%O of 0$T

*c Pear test pieces


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7ear testing

S,

N

O

MATEIA# -IAGONA

#

*))+

-IAGONA

#

*))+

#OA- .!/

*K&(+

H"N

A9


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Bcanning #lectron Microscopy *B#M

B#M image of Al"0$T gear

0onfirmation of 0$T presence in the matri1


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Pear test

Pi/ o/ 0i'. wear (e'(er


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0omparison of samples

S2!2)-

!26ta)/"

*&+

H"2-ht

66*&+

H"2-ht

66*&+

H"2-ht

66*&+

(. g (.% g (.& g

Beries / Beries Beries %

(00 /2 /& /

800 & /- /5

%00 %' 2

900 5% %& -

$000 5& 5( %%

$(00 5' 5 %-

$800 &% 5' 5%

$%00 &' & 5-$900 3 &' &/

(000 3- 3/ &3

((00 ' 3& 3(

(800 '' '( 33

(%00 -5 '3 '(

(900 -2 - '5

3000 23 -2 '2

& -&& 2&&& 2-&& 1&&& 1-&& +&&& +-&&&

1&

4&

3&

&

2&&

21&

"ei>"( 9o'')m*

S9i0i/> 0i'(a/.e )m*


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9esults

PROCES

SBEFORE HARDENING AFTER HARDENING

CNT *-+ (. (.% (. (.%

HVN ( 5% '

CNT *-+ 0( 03 05

WEAR RATE

*&.&2)+&.'#"% /.5#"% /5.#"%

CNT *-+ 0( 03 05

&.'#"% /.5#"% /5.#"%

ardness comparison

Pear rate comparison


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Tha), :;

design of spur gear

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