DESIGN AND MANUFACTURING OF

GEAR AND ITS APPLICATIONS

PROJECT REPORT
Submitted
By
ARYAN SHRIVA (1741018079)
KARTHIKS S NAIR (741018082)
ASHISH KUMAR DAS (1741018074)
PRATIK ROSHAN (1751018071)

Under the Guidance of

Prof. Premananda Pradhan

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 DEPARTMENT OF MECHANICAL ENGINEERING
INSTITUTE OF TECHNICAL EDUCATION AND RESEARCH,
SOA (Deemed to be University), Bhubaneswar, Odisha.
2019

ABSTRACT

The Design and manufacturing of gear is the most common type of gear widely used in mechanical
machineries, automobiles and for many other mechanical purposes.

The process starts with virtual modeling of the gears followed by analysis using SOLIDWORKS
2019 in CAD /CAM /CAE in lab B-116. The manufacturing has been done in Mechanical
Workshop.

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 CERTIFICATE

The laboratory report entitled “Design and manufacturing of gear” submitted by Aryan shriva
(1741018079) , Karthik s Nair (1741018082) , Ashish Kumar das (1741018074) and Pratik Roshan
(1851018071) is under the supervision and constant guidance of Prof. Premananda Pradhan ,
Mechanical Engineering department, Institute of Technical Education, SOA Deemed to be
University, Bhubaneshwar, Odisha.

Prof. Premananda Pradhan

Department of Mechanical Engineering
Institute of Technical Education and Research
SOA Deemed to be University
Bhubaneshwar, Odisha – 751030

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 ACKNOWLEDGEMENT

We have given our maximum effort and time to our project. However, it would not have been
possible without the kind support and help of many individuals. We would like to extend our
sincere thanks to all of them.

We are highly indebted to PROF. PREMANANDA PRADHAN for his guidance and constant
supervision as well as for providing necessary information regarding the project and also for his
support in completing the project .We would like express our gratitude towards our parents and
member of our organization (INSTITUTE OF TECHNICAL EDUCATION AND RESEARCH)
for their kind cooperation and encouragement which help us in completion of our project .We
would like to express our special gratitude and thanks to all lab and workshop assistants for giving
us such attention and time for the successful completion of our project.

Our thanks and appreciation also go to our classmates in developing the project and willingly
helping us out with their abilities.

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CHAPTER-1: TABLE OF CONTENTS: -
1.1 Abstract
1.2 List of figures

CHAPTER-2: INTRODUCTION: -
2.1 What is a gear?

CHAPTER-3: TYPES OF GEAR: -

1. Spur Gear.
2. Helical Gear.
3. Rack and Pinion.
4. Intersecting Bevel Gear.

CHAPTER-4: GEAR TRAINS: -

4.1 What is gear train?
4.2 Types of gear trains.
4.3 Simple gear trains.
4.4 Compound gear trains.
4.5 Planetary gear trains.

CHAPTER-5: DIFFERENT TYPES OF PROCESS USED IN

MANUFACTURING OF GEAR: -
5.1 3D Printing

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CHAPTER-6: SPUR GEAR MAKING: -
6.1. What is a gear?
6.2. 3D design
6.3. Required machine.
6.4. Procedure.
6.5. Precaution.
6.6. Applications.

CHAPTER-7: OUR GEAR MANUFACTURING: -

7.1. Gear Terminology
7.2. Problem
7.3. Solution
7.4. Solid works design
7.5. Key shot Rendering

Chapter 8: CONSTRUCTION: -
8.1. Materials
8.2. Why we choose ABS
8.3. Manufacturing process of spur gear
8.4. Reason for choosing milling process

Chapter 9: CONCLUSION & REFERENCES: -

9.1. Result & Discussion
9.2. Final project
9.3. Conclusion
9.4. References

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 CHAPTER-1

1.1 Abstract: -
A gear is a rotating machine part having cut teeth, which mesh with another
toothed part to transmit torque, in most cases with teeth on the one gear being
of identical shape, and often also with that shape on the other gear. Gear is used
for changing the direction through which power is transmitted (i.e. parallel,
right angles, rotating, linear etc.), changing the amount of force or torque,
changing RPM.
Spur gear is a very important type of gear. Spur gears are the most commonly
used gear type. They are characterized by teeth which are perpendicular to the
face of the gear and also the teeth are parallel to the axis of rotation.
In this project work, finally a spur gear was completed and every update were
given regularly.

1.2 List of Figures: -

Figure Title
1 Gears
2 Gear meshing
3 Spur gear
4 Spur gear terminology-1
5 Spur gear terminology-2
6 Dimensions of Spur gear
7 Rendering images
8 3D printing process
11.1 Manufactured Spur Gear

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 CHAPTER-2

INTRODUCTION: -
WHAT IS A GEAR?
Power transmission is the movement of energy from its place of generation
to a location where it is applied to performing useful work.

A gear is a rotating machine part having cut teeth or, in the case of a cogwheel,
inserted teeth (called cogs), which mesh with another toothed part to transmit torque.
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.[1] Two or more meshing gears, working in a
sequence, are called a gear train or a transmission. A gear can mesh with a linear
toothed part, called a rack, producing translation instead of rotation.
The gears in a transmission are analogous to the wheels in a crossed,
belt pulley system. An advantage of gears is that the teeth of a gear prevent slippage.
When two gears mesh, if one gear is bigger than the other, a mechanical advantage
is produced, with the rotational speeds, and the torques, of the two gears differing in
proportion to their diameters.
In transmissions with multiple gear ratios—such as bicycles, motorcycles, and
cars—the term "gear" as in "first gear" refers to a gear ratio rather than an actual
physical gear. The term describes similar devices, even when the gear ratio is
continuous rather than discrete, or when the device does not actually contain gears,
as in a continuously variable transmission

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 CHAPTER-3

TYPES OF GEAR: -
According to the position of axes of the shafts
1. Spur Gear
2. Helical Gear
3. Rack and Pinion
4. Bevel Gear

1. Spur gear: -

Used in Electric
screwdriver,
Transmit power oscillating
Teeth is parallel
from one shaft sprinkler,
to axis of
to another windup alarm
rotation.
parallel shaft . clock, washing
machine and
clothes dryer.

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 Driver driven
External and internal spur gear:-

Helical gear: -
The teeth on helical gears are cut at an angle to the face of the gear.
This gradual engagement makes helical gears operate much more smoothly
and quietly than spur gears.
One interesting thing about helical gears is that if the angles of the gear teeth
are correct, they can be mounted on perpendicular shafts, adjusting the
rotation angle by 90 degrees.

2. Helical gear: -

3. Rack and pinion:-

❖ Rack and pinion gears are used to convert rotation (From the pinion)
into linear motion (of the rack).

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❖ A perfect example of this is the steering system on many cars.

4. Bevel Gear: -

They are
usually
Bevel gears are
mounted on The teeth on
useful when
shafts that are bevel gears can
the direction of
90 degrees be straight,
a shaft's
apart, but can spiral or
rotation needs
be designed to hypoid.
to be changed.
work at other
angles as well.

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Nomenclature of spur gear: -

Nomenclature: -
1: Pitch surface: The surface of the imaginary rolling cylinder (cone, etc.) that the
toothed gear may be considered to replace.
2: Pitch circle: A right section of the pitch surface. 3: Addendum circle: A circle
bounding the ends of the teeth, in a right section of the gear.
4: Root (or dedendum) circle: The circle bounding the spaces between the teeth, in
a right section of the gear.
5: Addendum: The radial distance between the pitch circle and the addendum
circle.
6: Dedendum: The radial distance between the pitch circle and the root circle.
7: Clearance: The difference between the dedendum of one gear and the
addendum of the mating gear.
8: Face of a tooth: That part of the tooth surface lying outside the pitch surface.
9: Flank of a tooth: The part of the tooth surface lying inside the pitch surface.
10: Circular thickness (also called the tooth thickness): The thickness of the tooth
measured on the pitch circle. It is the length of an arc and not the length of a
straight line.
11: Tooth space: pitch diameter the distance between adjacent teeth measured on
the pitch circle.

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 12: Backlash: The difference between the circle thickness of one gear and the
tooth space of the mating gear.

13: Circular pitch (Pc): The width of a tooth and a space, measured on the pitch
circle.
𝑝𝑐 = 𝜋𝐷/𝑁
14: Diametral pitch (Pd): The number of teeth of a gear unit pitch diameter. The
diametral pitch is, by definition, the number of teeth divided by the pitch diameter.
That is,
Where
Pd = diametral pitch
N = number of teeth 𝑃𝑑 = 𝑁/𝐷
D = pitch diameter
15: Module (m): Pitch diameter divided by number of teeth. The pitch diameter is
usually specified in inches or millimeters; in the former case the module is the
inverse of diametral pitch. m = D/N

VELOCITY RATIO OF GEAR DRIVE: -

d = Diameter of the wheel
N =Speed of the wheel
ω = Angular speed

velocity ratio (n) =ω1/ω2=N2/N1=d1/d2

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 CHAPTER- 4

4.1 What is GEAR TRAIN?

1) A gear train is two or more gear working together by meshing their teeth and
turning each other in a system to generate power and speed.
2) It reduces speed and increases torque.
3) Electric motors are used with the gear systems to reduce the speed and
increase the torque.

4.2 Types of gear trains: -

1. Simple gear train.
2. Compound gear train.
3. Planetary gear train Simple Gear Train.
• The most common of the gear train is the gear pair connecting parallel
shafts. The teeth of this type can be spur, helical or herringbone.
• Only one gear may rotate about a single axis.

4.3 Simple gear train: -

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4.4 Compound gear trains: -

For large velocities,

Two or more gears
compound
may rotate about a
arrangement is
single axis.
preferred .

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4.5 Planetary gear trains (epicyclic gear train):-

* In this train, the blue gear has six times the diameter of the yellow gear.
*The size of the red gear is not important because it is just there to reverse the
direction of rotation.
* In this gear system, the yellow gear (the sun) engages all three red gears (the
planets) simultaneously.
* All three are attached to a plate (the planet carrier), and they engage the inside of
the blue gear (the ring) instead of the outside.
* Because there are three red gears instead of one, this gear train is extremely
rugged.
*planetary gear sets is that they can produce different gear ratios depending on
which gear you use as the input, which gear you use as the output, and which one
you hold still.
* They have higher gear ratios.
* They are popular for automatic transmissions in automobiles.
* They are also used in bicycles for controlling power of pedaling automatically or
manually.
* They are also used for power train between internal combustion engine and an
electric motor.

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 CHAPTER -5
DIFFERENT TYPES OF PROCESS USED IN
MANUFACTURING OF GEAR: -

There are many different branded 3D printing processes, that can be grouped into
seven categories:[58]

• Vat photopolymerization

• Material jetting

• Binder jetting

• Powder bed fusion

• Material extrusion

• Directed energy deposition

• Sheet lamination

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 CHAPTER -6
SPUR GEAR MAKING: -
6.1 WHAT IS GEAR?
Gear is one of the machine tool elements which is an integral and inevitable part of
power transmission system.

6.2 REQUIRED TOOLS

1: BENCH VICE
2: FILE

6.3 REQUIRED MACHINES

1: 3D printer

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6.4 PROCEDURE: -

• make a 3D design model

• save the file as .STEP

• open the .STEP file in the software

• Then the gear making process

occured.

• Finally the gear is filled to get a

100% clean and smooth surface.

6.5 PRECAUTION: -
1. Safety dress codes are maintained.
2. All the electric connections are checked.
3. Proper working material are need to use.
4. Rotation of crank is counted very carefully to maintain equal distance of the
teeth.
5. All the machines are to be shut down after making this.

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6.6 APPLICATION: -
1. Automobile
2. Power transmission distributors
3. Electronics
4. Printing
5. Robotics
6. Marine steering

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 CHAPTER-7
7.1 WHAT IS 3D printing
Acrylonitrile Butadiene Styrene (ABS) is used by 3D FDM or FFF printers and
comes in the form of a long filament wound around a spool. Operating the 3D
printer is fairly simple: the ABS strand is guided into an extrusion head or
extruder that heats the ABS plastic to its melting point in order to liquefy it.

7.2 NOMENCLATURE OF 3D printing: -

3D printing or additive manufacturing is a process of making three dimensional
solid objects from a digital file.

The creation of a 3D printed object is achieved using additive processes. In an

additive process an object is created by laying down successive layers of material
until the object is created. Each of these layers can be seen as a thinly sliced
horizontal cross-section of the eventual object.

3D printing is the opposite of subtractive manufacturing which is cutting out /

hollowing out a piece of metal or plastic with for instance a milling machine.

3D printing enables you to produce complex shapes using less material than
traditional manufacturing methods.

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7.4 REQUIRED MACHINE: -
*Grinding Machine

*File

*Driller

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7.5 PROCEDURE:-

• Making a3D model

• saving the file as .STEP

• opening the .STEP file in the

software

• printing in 3D printer

• Surface finishing by
File

7.6 PRECAUTIONS: -
*Wear apron and eye protector glass.
* Keep the finger well back from grinding wheel.
* Never hold the job with cloth.

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 CHAPTER-8

OUR GEAR MANUFACTURING: -

*We are making a spur gear mechanism.
8.1 Spur Gear: -
Spur gears are the most commonly used gear type. They are characterized by teeth
which are perpendicular to the face of the gear. Spur gears are by far the most
commonly available, and are generally the least expensive.
* Teeth is parallel to axis of rotation
* Transmit power from one shaft to another parallel shaft
* Least expensive

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8.2 Applications of Spur Gear: -
* Metal cutting machines
* Power plants
* Marine engines
* Mechanical clocks and watches
* Fuel pumps
* Washing Machines
* Gear motors and gear pumps
* Rack and pinion mechanisms
* Material handling equipments
* Automobile gear boxes
* Steel mills
* Rolling mills

8.3 Gear Terminology: -

Pitch surface: The surface of the imaginary rolling cylinder (cone, etc.) that the
toothed gear may be considered to replace.
Pitch circle: A right section of the pitch surface. Root (or dedendum) circle: The
circle bounding the spaces between the teeth, in a right section of the gear.
Addendum: The radial distance between the pitch circle and the addendum circle.
Dedendum: The radial distance between the pitch circle and the root circle.

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Clearance: The difference between the dedendum of one gear and the addendum of
the mating gear.
Face of a tooth: That part of the tooth surface lying outside the pitch surface.
Flank of a tooth: The part of the tooth surface lying inside the pitch surface.
Circular thickness (tooth thickness): The thickness of the tooth measured on the
pitch circle. It is the length of an arc and not the length of a straight line.

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Tooth space: The distance between adjacent teeth measured on the pitch circle.
Backlash: The difference between the circle thickness of one gear and the tooth
space of the mating gear.
Module ‘m’: Pitch diameter divided by number of teeth. The pitch diameter is
usually specified in inches or millimeters; in the former case the module is the
inverse of diametral pitch.
Fillet: The small radius that connects the profile of a tooth to the root circle.
Pinion: The smallest of any pair of mating gears. The largest of the pair is called
simply the gear. Velocity ratio: The ratio of the number of revolutions of the
driving (or input) gear to the number of revolutions of the driven (or output) gear,
in a unit of time.
Pressure angle: Pressure angle in relation to gear teeth, also known as the angle of
obliquity, is the angle between the tooth face and the gear wheel tangent. It is more
precisely the angle at a pitch point between the line of pressure (which is normal to

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the tooth surface) and the plane tangent to the pitch surface.

8.5 Drawing and dimension: -

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 Final design of Spur Gear

Here, Module =2,

Number of teeth = 25,
Outer Diameter = 40mm,
Shaft Diameter = 6mm,
Gear Hole = 6mm (for 2 gears) & 6mm (for 1 gear)

8.6. Rendering Images: -

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 CHAPTER-9

* Materials
* Why we ABS
* Manufacturing process
* Procedure
* Final project
Materials:
1.ABS
2. wood

9.2Why we ABS?
ABS mean Acrylonitrile Butadiene Styrene (ABS). ABS (Acrylonitrile Butadiene
Styrene) is part of the thermoplastic polymer family. As its name implies, ABS is
created from Acrylonitrile, Butadiene and Styrene polymers. It is a material
commonly used in personal or household 3D printing, which is done using
primarily FDM or FFF. This common thermoplastic material is popular because it

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is easy to use with a desktop 3D printer, but also because it has some great
material properties.

9.3 MANUFACTURING PROCESS OF SPUR GEAR:

1. 3D printing

9.4 Reason for choosing ABS:

Using ABS (Acrylonitrile butadiene styrene) filament gives you a harder and more
durable object that is also more temperature resistant than PLA. With ABS you can
usually go over 100 degrees Celsius before the 3D printer part starts to soften
unlike 65-70 with PLA.

9.5 3D printing process:

This is one of the initial and best known and metal removal process for making
gears. This method requires the usage of a milling machine. It is also to be noted
that this method can produce nearly all types of gears. The method involves the use
of a form cutter, which is passed through the gear blank to create the tooth gap.
This method is right now used only for the manufacture of gears requiring very
less dimensional accuracy. To put it correctly this method is currently outdated.

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 CHAPTER-10

10.1 Result & Discussion:

By analyzing the selected problem, all steps are completed to manufacture a spur
gear. All dimensions are taken based on the problem. After completing several
machining processes expected spur gear is found. For light shock the value of NSF
should be 1.25< NSF <1.5. The value of NSF of the designed gear is within the
range. So, the design will be safe from the failure.

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10.2 Conclusion:
By performing this project, we had learnt the design of spur gear, analysis of a
spur gear terminology, solving related problem, calculating safety factor of it &
the safe arrangement of it. In future it will be helpful for us to choose the right
gear among various types gear.

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 CHAPTER-11

11.1 References

• www.google.com
• www.wikipedia.com
• FAIRES VIRGIL MORING, “DESIGN OF MACHINE ELEMENTS”, 4th
edition, The Macmillan Company, New York/Collier-Macmillan Limited,
London
• Jain R.K., “Production Technology”, 16th edition, 2B, Nath Market, Nai
Sarak, Delhi-110006
• http://www.brighthubengineering.com/manufacturin g-technology/7118-
gear-manufacturing-methods

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