3.

​Major components of project assembly

​ Assembly of project
From the above assembly drawing we can get the major components as:-

1. Input pinion shaft

2. Intermediate pinion shaft
3. Intermediate gear
4. Output gear
5. Output shaft bottom
6. Output shaft top
7. Output pinion (L.H and R.H)
8.Housing
9.Base frame
10.Air breather

3.1 ​ ​Gears

A ​gear​ is a rotating machine part having cut teeth, or in the case of a cogwheel,
inserted teeth , which mesh with another toothed part to transmit . Geared devices
can change the speed, torque, and direction of a power source. Gears almost
always produce a change in torque, creating a mechanical advantage , through
their gear ratio, and thus may be considered a simple machine. The teeth on the
two meshing gears all have the same shape.Two or more meshing gears, working
in a sequence, are called a gear train or a transmission​.

Types of Gear:-
For parallel shaf​t
- spur gear
- Single and double Helical gear
For non parallel intersecting gear
- Helical bevel gear
Non parallel non intersecting
- Skew bevel gear or spiral gear

All the gears used in the project were single helical gear. They had to transfer
motion between two parallel shafts due to which spur gear was an option but it
was’nt used because helical gear is superior to spur gear in many ways-
-Helical gears have better meshing
- Helical gear have more load carrying capacity
- It can be used at comparably higher speed without much of noise
-It also has more life
 Different steps of gear manufacturing

Cut forge bar of suitable dia ,10 mm allowance on each side

[bandsaw blade]

Turn gear tooth OD, keep 10 mm undersize

[Lathe/VTL]

Drilling and tapping

[Radial drilling machines]

Teeth cutting
[Gear hobbing machine]

Debur & chamfering on teeth suraface (.25m)

[cuttoff wheel]

Chamfering teeth width(.15m)

[Hand grinder]

No carbpaste bore & side of gear width

(applied where hardness not required)

Stress relieving ( above 12 module of gear)

case carburizing+quenching+tempering (Inspection for case depth and

hardening)
[58 to 60 HRC]
 Cleaning of gear through hot blasting/ hot force water

Turn bore as per drawing (leaving grinding allowance)

[VTL]

Grind bore and face as per drawing and other face

[Rotary surface grinding machine]

Keyway cutting
[Fromag ,Shapping m/c]

Grind to to​lerance quality DN5 a per DIN3​960

Inspect for runout, dimension check,profile report, DP test for crack

Specifications of different gears being used in the project

- ​Input pinion shaft​ ​output pinion

​Details
- ​Intermediate Gear​ - ​Intermediate pinion shaft

Details

Output gear

There is one more gear present as output gear having

no of teeth – 56 module – 9
helix direction – LH

Material of the Gears and gear shafts

18 CRNIMO7-6

Heavy-duty arbors, bushings, wear pins, bearings, sprockets, ​gears​ and ​shafts​ etc. Or can
be used for high tensile applications uncarburised but through hardened and
tempered.Good through hardening properties with excellent toughness due to the low
carbon and high alloy content, also suitable for Nitriding.
Carbon 0.18%,Silicon 0.20%,Manganese 0.70% Chromium 1.65% Nickel 1.55%
Molybdenum 0.30%
The material is used for all the gears and pinion shafts because of good machinability,
strength and hardening properties.

En 9

En 9 is an example of medium plain carbon steel.

Steel Grade C Si Mn P S
EN9/070M55 0.50-0.60 0.10-0.40 0.50-0.90 max 0.05 max 0.05

EN9​ is used commonly for many general engineering ​applications​. Typical ​applications
include, ​shafts​, axes, knives, bushes, crankshafts, screws, sickles, wood working drills and
hammers.

EN 19

EN19​ is a high quality alloy ​steel​ with tensile strength. With a combination of good ductility
and shock resistance, ​EN19​ is suitable for applications with very high loading such as
engine gear boxes. ... The ​material​ lends itself well to any application where strength is a
primary consideration.

Steel Grade C Si Mn P S Cr Mo
EN19/708M
0.36-0.44 0.10-0.40 0.70-1.00 max 0.035 max 0.040 0.90-1.20 0.15-0.25
40

EN 24

EN24 is a very high strength steel alloy which is supplied hardened and tempered. The
grade is a nickel chromium molybdenum combination - this offers high tensile steel
strength, with good ductility and wear resistance characteristics. With relatively good
impact properties at low temperatures.

Typical Applications:
High strength shafts
Punches & dies
Drill bushings
Retaining rings
Gears
- ​Cutting of forged shafts​ is done through bandsaw blade using cutting fluid
according to the length and dia required with some tolerance . There are in total 5
bandsaw blade machines in the company branch where i got trained .

- After cutting the piece as per the size requirement the piece is sent to VTL
machines where its outer dia is prepared.

- After this the piece is sent to radial ​drilling ​machine where drilling and tapping of
the piece is done according to requirement .

Tapping​ - ​A tapped hole is a hole drilled prior to a machine screw being inserted.​A
tapped hole is similar to a pilot hole, except that it is usually larger, and has threads
cut into the inside surface of the hole.Tapped holes are used in metals where a nut
and bolt cannot be used.

​Tapped hole shown in right image, drilled in left

Hobbing process

- In the next process the gear and pinion shaft goes for hobbing process where
different hobbing machines as shown in the file earlier like G&E GH11, pfauter
PA300, GH05 or any other hobbing machine depending upon the module , bore dia,
gear dia of the gear.
 ​Gear hobbing manual

- In the manual which is made for every other gear hobbing different values are
indicated through various calculation.like :-

- ​Index gear train​- This value depends upon the number of teeth required in the
gear. It also depends upon one constant called index constant which remains fix for
different hobbing machines.
Index gear trainformula = Index constant × Number of start of
hob
Number of teeth
In the given picture above index constant is 24.

- ​Differential gear train​ is responsible for the helix angle required on the gear.

Differential gear train = machine differential constant ×sin β

module ×numer of start
here differential constant for different machines, number of start is starts in hob
which was 1 in our case.
Β – helix angle

- Measurement over teeth gives the value of length over given number of teeth like
m4, m7 etc. When number of teeth is more then measurement over teeth remains
the measure of more number of teeth.

- ​Hob angle setup ​– For the hob angle set up two angles are taken into
consideration. One is hob lead angle and the second is helix angle required with the
helix direction require.
If both the angles are in same direction i.e LH or RH then the value of angles will
be decreased to get the required hob angle.
If both the angles are different then the values will be subtracted and the finally the
hob will be given the resultant angle and direction.
For ex if hob lead angle= 5 degree RH and helix required is 15 degree LH then
final hob angle =15+5 = 20 degree LH .

To identify the direction of helix

Allign the gear in a way that the shaft is perpendicular to your eye sight, now if the
gear looks going in right side of you then the gear is right hand gear and vice-versa.

- After hobbing process the gear goes for chamfering where all the corners and
edges of the teeth got chamfered through hand grinder.
Heat treatment step

After chamfering process the gears and pinions were prepared for heat treatment
where anticarb paste got applied where we do not need much hardness i.e leaving
the gear teeths at the bore and side of the gear.

Now the gear reaches the heat treatment area where it is to be case hardened and
tempered.

STEP 1 Firstly the gear is put in the pit type case carburizing furnace where the
temperature of the gear is taken to 920°c after some heating it reaches boost phase
succeded by diffusion phase. Later it its temperature made to drop to 840°c the
hardening temperature.

STEP 2 After keeping the gear in the furnace for few more hours depending upon
the thickness of the gear. Later oil quenching of the gear is done where the gears
suddenly gets cooled in the oil tank with agitator. After taking out the gear from
quenching tank the surface of the gear and pinion shaft is grinded slightly and the
hardness is measured by portable hardness tester machine.

STEP 3 After satisfactory results in 2​nd​ step, the gears and pinion shaft are
tempered at suitable temperature. It is to be to be noted that
tempering temp increases----------brittleness decreases but strength also decreases

Now through shot blasting technique and hot water force thye gear is cleaned and
prepared for next steps.

- After heat treatment some gear runout comes in place, to tackle thet the bore of
the gear is prepared through VTL leaving grinding allowance. After this the gear
goes to the rotary surface grinder where bore and face of the shaft and gear is
grinded as per the drawing.

- Now ​keyway​ in the gear is cut through shaper machine or fromag machine.Later
the gear is entered in the shaft and sent to the hofler machines.

- now the gear reaches hofler rapisd 1250 l ii where most important phase the
grinding of the teeth of the gear and pinion is done. Here the gear teeth are
prepared to quality DN5 as per DIN3960. Then in the same machine the runout
dimensions are checked and profile report generation , DP test for crack are done.

Now gears and the pinion shafts are ready to be sent for assembly.