INTRODUCTION

Throwg this document it is developed a gearbox adapted for the industry. The development
and implementation of gearboxes in the industrial sector play a crucial role in the fields of
computer-aided manufacturing. Gearboxes are mechanical devices that transmit power and
control the speed and torque of rotational motion between different components of a machine.
They are widely used in various industries, including automotive, aerospace, manufacturing,
and robotics.

Computer-aided manufacturing (CAM) is another critical area where gearboxes find their
application. CAM involves the use of computer software and hardware to control and
automate the manufacturing processes, such as machining, assembly, and quality control.
Gearboxes are essential components in many machines used in CAM systems, enabling
precise control of rotational speed and torque, ensuring accurate and consistent
manufacturing operations.

The development of gearboxes implemented in the industry requires a multidisciplinary

approach, combining mechanical engineering principles, advanced materials, and
computer-aided design (CAD) techniques. Engineers and researchers work collaboratively to
design, analyze, and optimize gear systems to meet specific performance requirements, such
as torque capacity, speed range, noise reduction, and efficiency.
CHAPTER I: THEORETICAL FRAMEWORK

1.1 Manufacture
Manufacturing is a fundamental process in the production of mechanical components and
systems. It involves the transformation of raw materials into finished products through various
techniques and processes. The manufacturing industry plays a crucial role in providing
essential goods and products for different sectors, including automotive, aerospace,
electronics, and machinery. In the context of the integrative project, understanding the
principles of manufacturing is essential for selecting suitable materials and processes for
fabricating the gearbox components, including the gears and other parts.

1.2 Lathe
A lathe is a machine tool used for shaping and machining cylindrical workpieces. It operates
by rotating the workpiece while a cutting tool is applied to remove material and create the
desired shape. Lathes are versatile machines used for various operations, such as turning,
facing, threading, and drilling. In the context of the project, knowledge of lathe operations is
essential for fabricating certain gearbox components and achieving precise dimensions for
proper gear functionality.

1.3 Milling machine

A milling machine is a versatile machine tool used to remove material from a workpiece using
rotary cutters. It operates by moving the workpiece relative to the cutter's rotating blades,
enabling the creation of complex shapes and features. Milling machines are widely used in
manufacturing and play a crucial role in fabricating intricate parts with high precision. In the
context of the project, understanding milling machine operations is crucial for manufacturing
certain gearbox components, ensuring proper gear tooth profiles and dimensions.
1.4 CAM
The term CAM (Control of Mechanical Actuator) is commonly used to refer to a mechanism
that controls the selection of different gear ratios in an automatic transmission. However,
creating a homemade automatic gearbox with acrylic gears obtained through a laser cutter
poses several technical challenges and limitations that need to be considered.

Firstly, acrylic gears may not be suitable for high-power and high-strength transmission, as
acrylic is a relatively brittle material compared to the metals used in conventional
transmissions. This means that the homemade gearbox may not be able to handle significant
levels of torque and power.

Additionally, the precision and strength of laser-cut gears may be questionable compared to
industrially machined gears. This can negatively impact the performance and durability of the
gearbox, especially under heavy load conditions.
Regarding the CAM mechanism itself, it controls the position of synchronizers and clutches in
an automatic gearbox to achieve gear shifts. The CAM is synchronized with the output shaft
of the transmission and uses a series of lobes to sequentially move the gears and clutch
elements. The shape and profile of the lobes on the CAM are specifically designed to control
the precise movement and position of the transmission components.

In the case of this project, gearbox with acrylic gears, it would be necessary to design and
manufacture a suitable CAM mechanism to control the gear shifts. This would require
advanced knowledge of mechanical design and a deep understanding of the dynamics of an
automatic transmission.
A laser cutter is a machine that uses a concentrated and high-powered laser beam to cut
various materials. The laser cutting process involves directing the laser beam through a focal
lens to focus it on a very small and high-energy point. This generates intense heat in the
target material, causing it to melt, vaporize, or burn, enabling precise cuts.

The operation of a laser cutter is based on controlling an optical system composed of mirrors
and lenses that direct and focus the laser beam. The laser beam is generated through a laser
tube that contains an active medium (such as CO2, fiber optics, or solid-state laser) that emits
the laser light. The laser power and wavelength depend on the type of laser tube used.

1.5 Gearbox
In the words of Redacción autofichas (2023) "An automatic gearbox or automatic
transmission is a type of transmission that shifts gears automatically, without the need for the
driver to do so manually. Instead of having to depress the clutch pedal and manipulate the
gearshift, the driver only has to select the desired driving position. The operation of the
automatic gearbox is based on a series of mechanical, electronic and hydraulic components
that work together to change gears automatically. The heart of the automatic gearbox is a set
of planetary gears that combine to provide different gear ratios".

“There are many different types of gears that can be used in different places. Therefore, the
application of gears is diverse, and we cannot give a concrete list. We can see that the
mechanical industry has rapid development. There is no doubt that the market demand for
gears that are used in industrial applications is increasing. Obviously, the application of gears
is quite wide. For example, they can be used in fertilizer industry, railway industry, printing
industry and earthmoving industry, etc. Except for these industries, there are also many other
industries where gears can play quite an important role. Next, let's look at some of the
applications of gears” (From Transmisión Automática, 2020)

1.6 CAD part design

“SOLIDWORKS is a 3D CAD (computer-aided design) software for modeling 3D parts and
assemblies and 2D drawings. The software offers a range of solutions to cover all aspects
involved in the product development process. Its products offer the ability to create, design,
simulate, manufacture, publish and manage design process data. SOLIDWORKS work in the
product development process is very specific, the solutions help speed up the process saving
time and money giving way to product innovation. Where in most companies the value chain
is a sequential process where they need to finish previous phases to start new ones,
SOLIDWORKS solutions allow the process to be run in parallel rather than sequentially, in
order to save time and make better business decisions by creating better designs.

SOLIDWORKS is the world standard 3D CAD present in most companies worldwide.

Because of this, communicating with your customers and suppliers presents no compatibility
problems and facilitates the work of the entire design process. There are currently more than
3 million users working with SOLIDWORKS and the number is growing daily. SOLIDWORKS
CAD 3D allows to significantly reduce design cycle times, saves time and costs, and
increases the quality of designed products. Thanks to the tools provided by this design
software, you can be more productive and get products to market faster. It also features an
intuitive and easy-to-use interface that helps you quickly transform ideas into real products

SOLIDWORKS on the 3DEXPERIENCE® platform offers a new design experience focused

on enabling users to create innovative products in a truly collaborative, connected
environment. The 3DEXPERIENCE Works, is a collaborative platform available in the cloud
that enables SOLIDWORKS users to create their 3D designs, product analysis and simulation
with remote access and in a collaborative environment. It is a portfolio of applications that is
tailored to the needs of SOLIDWORKS users and small to medium-sized businesses.

Both CAD and non-CAD users, including executives, design team leaders and project
managers, can share information, participate in the design process and easily add data from
any source to help make design decisions faster and on any location and device. For design
professionals looking to create and collaborate without constraints, SOLIDWORKS solutions
on the 3DEXPERIENCE platform offer them an instinctive, powerful modeling environment
focused on the four key features of conceptual design. Extending SOLIDWORKS
functionality, making design accessible to the rest of the enterprise”(SolidBi, 2023)

1.7 Part process simulation (lathe and milling machine)

Part process simulation is a vital aspect of modern manufacturing, where computer-based
simulations are used to optimize and validate machining operations before actual production.
In the context of the integrative project, part process simulation for both lathe and milling
machine operations is crucial for ensuring the accuracy and efficiency of the gear
manufacturing process.

1.7.1 Lathe Process Simulation:

Lathe process simulation involves using specialized software to model and simulate the
machining operations performed on the lathe. By inputting the design specifications and
toolpath parameters, the simulation software can generate a virtual representation of the lathe
operation, including material removal, tool movements, and resulting part shape. This
simulation helps identify potential issues such as tool collisions, excessive material removal,
and errors in the machining process before it is actually performed on the lathe. It allows
engineers to optimize cutting parameters, choose suitable cutting tools, and predict the final
part's dimensions and surface finish.

1.7.2 Milling Machine Process Simulation:

Similarly, milling machine process simulation utilizes software to simulate the milling
operations on the workpiece. The simulation considers factors like tool geometry, toolpath
strategy, and material properties to predict the machining results. By running the simulation,
engineers can visualize the material removal process, analyze cutting forces, and identify
potential problems like chatter and tool breakage. This allows for adjustments in tool
selection, cutting strategies, and feed rates to optimize the milling process and achieve the
desired part dimensions and surface quality.
Overall, part process simulation for both lathe and milling machine operations provides
valuable insights into the machining process's efficiency and accuracy. By identifying and
resolving potential issues beforehand, the simulation ensures that the actual manufacturing
process is more reliable, reduces material waste, and minimizes costly errors. This
technology-driven approach enhances the integrative project's success in developing a
functional gearbox with precisely machined gear components.
CHAPTER II: METHODOLOGY
The option involves utilizing the SolidWorks application, renowned for its powerful 3D
modeling and design capabilities. By leveraging SolidWorks, we can meticulously design our
figure based on a detailed plan, taking advantage of the software's sophisticated tools and
functionalities. Once the design is complete, we can effortlessly export it as a DXF drawing,
preserving the intricate details and dimensions. Upon obtaining the DXF drawing, we can
seamlessly transfer it to RDworks, where we proceed to set the parameters necessary for the
laser cutting process. This pivotal step includes determining the appropriate power levels for
cutting each of the gears, as well as the walls of our box, ensuring precise and accurate
results. Furthermore, RDworks enables us to customize the power settings based on the
specific material being used, allowing for optimal cutting performance and efficient material
utilization.

In addition to cutting gears and box walls, RDworks empowers us to create the lever
necessary for the gear shift, adding a functional and aesthetically pleasing element to our
figure. With its ability to finely control the laser's power, speed, and focus, RDworks ensures
that the lever is crafted with utmost precision, facilitating smooth and reliable gear shifts.
Overall, the combination of RDworks and SolidWorks provides a seamless workflow for
designing and manufacturing intricate figures with laser precision. This integration of software
tools not only streamlines the creative process but also ensures that the final output adheres
to the highest standards of accuracy and craftsmanship. Whether utilizing RDworks' internal
drawing tools or leveraging the advanced capabilities of SolidWorks, the end result is a
meticulously crafted figure, complete with intricately cut gears, precisely fabricated box walls,
and a functional gear shift lever, all coming together to exemplify the harmonious fusion of
creativity and technology. As we embrace the boundless possibilities offered by these
software solutions, we embark on a journey of ingenuity, pushing the boundaries of design
and manufacturing to new heights.
PROCESS
1. The first part of the gearbox development was the planning of the materials to be used
and the design to be implemented. Acrylic was chosen because it can be
manufactured more easily than any other material, and it is considerably cheaper per
square meter. The acrylic has a thickness of 3 millimeters to be successfully cut with
the CO2-powered laser cutter. Therefore, the raw material used will be acrylic due to
the benefits and aesthetics it provides.
2. Consequently, after the gearbox design was proposed, the chosen design was passed
to CAM for further processing. The main functionality of the gearbox relies on gears,
which will be cut from acrylic. The design of each gear was created using the
SolidWorks design program, and machining simulation for the gears using the milling
machine was initiated within the same software. The number of teeth for each gear
varied depending on its type, with 12, 15, 18, 21, and 24 teeth options. All gears were
designed with their respective characteristics in the program and incorporated into the
complete software model of the gearbox.

12 teeth
15 teeth

18 teeth
 21 teeth

24 teeth

3. To establish the connection between the computer and the laser cutter, the program
called RDWORKS was implemented. In this program, the design of each gear tooth
was placed, enabling its use within the laser cutter. The connection process is
straightforward, involving the simple act of connecting a USB cable from the computer
to the laser cutter for the acrylic. The maximum thickness that the laser cutter can
handle in its cuts is 9 millimeters. Once the computer is connected to the cutter via the
cable, the next step is to load the design and adjust the settings in the program. This
 includes specifying where to apply roughing and finishing operations, as well as
indicating all the internal cuts within the shape.
4. Once all the gears were loaded into the laser cutter, the machine was activated to
commence the cutting process of the pieces to be used. Each gear was cut twice to
ensure an adequate number of units for assembling the complete gearbox. The acrylic
material was carefully positioned, and the entire work area to be used was marked,
defining the space where the laser cutter would perform all the movements in the X
and Y directions to create the desired shape.
CHAPTER III: RESULTS
The results of the integrative project for the development of a gearbox adapted for the
industry are presented based on the theoretical framework and methodology outlined in the
previous sections. The project focused on designing and implementing a gearbox using
acrylic gears obtained through a laser cutter, with a particular emphasis on the integration of
CAD (Computer-Aided Design) and CAM (Computer-Aided Manufacturing) techniques.

Gearbox Design and Manufacture:

The initial phase of the project involved the planning of materials and design implementation.
Acrylic was selected as the material of choice due to its ease of manufacturing and
cost-effectiveness. The acrylic used had a thickness of 3 millimeters, which allowed it to be
successfully cut using the CO2-powered laser cutter. The design of each gear was created
using the SOLIDWORKS design program, and the gears' machining simulation was
performed within the same software.

Different gear options with 12, 15, 18, 21, and 24 teeth were designed, each catering to
specific gear ratios required for the gearbox's functioning. The complete software model of the
gearbox incorporated all the gears with their respective characteristics. The gears were then
loaded into the RDWORKS program, which facilitated the connection between the computer
and the laser cutter. This program allowed the gears' designs to be translated into cutting
instructions for the laser cutter.

Evaluation of Gearbox Performance:

The performance evaluation of the gearbox involved several tests to assess its efficiency,
reliability, and gear shifting capabilities. The gearbox was subjected to varying torque and
load conditions to analyze its ability to handle different power levels. Additionally, gear shifting
tests were conducted to determine the gearbox's smoothness and accuracy during gear
transitions.

The gearbox demonstrated satisfactory performance under normal operating conditions,

exhibiting smooth gear shifts and consistent rotational motion. However, it was observed that
the acrylic gears had limitations in handling extremely high-power and high-strength
transmission compared to conventional metallic gears.

VIDEOS
https://drive.google.com/drive/folders/1UIJpDXT377_Fr7xg5zwLBg5jfTSJeDcf?usp=sharing
CONCLUSIONS

Gael: In conclusion, the development of gearboxes implemented in the industry for the
classes of CAM and computer-aided manufacturing is a vital area of research and innovation.
By understanding the principles, design considerations, and applications of gear systems,
engineers and students can contribute to the advancement of mechanical power transmission
technology, optimizing machine performance and driving progress in various industries.

Jorge: Furthermore, the integration of computer-aided manufacturing (CAM) tools, such as

the RDWORKS program used in this project, exemplifies how advancements in technology
have revolutionized gearbox development. CAM software allows for seamless collaboration
between digital design platforms and physical manufacturing processes, streamlining the
production workflow and reducing manual errors. As industries move towards automation and
smart manufacturing, the combination of gear systems with cutting-edge CAM technologies
opens up new possibilities for optimizing production efficiency, reducing costs, and ensuring
consistent quality across the manufacturing line. Embracing such innovations is vital for
staying competitive in the rapidly evolving landscape of modern engineering and
manufacturing.
Cinthia: The exploration and understanding of gearboxes and their integration with
computer-aided manufacturing represent a compelling avenue for researchers, engineers,
and students to contribute to the evolution of mechanical power transmission. As technology
continues to advance, the potential for optimizing gear designs, leveraging innovative
materials, and applying sophisticated CAM techniques promises to revolutionize industries
and reshape the future of machinery and automation. By investing in this field of study, we
pave the way for enhanced performance, energy efficiency, and sustainability, propelling us
towards a more sophisticated and interconnected world of engineering excellence.

Jorge: In conclusion, the integrative project has successfully demonstrated the feasibility of
designing and implementing a gearbox adapted for the industry, utilizing acrylic gears
fabricated through a laser cutter. The project's multidisciplinary approach, combining
mechanical engineering principles, advanced materials, and computer-aided design
techniques, has proven crucial in achieving a functional gearbox. While the acrylic gears have
shown limitations in handling extremely high-power and high-strength transmission, the
project serves as a foundation for further research and optimization. Future iterations may
explore alternative materials or advanced manufacturing techniques to enhance the gearbox's
torque capacity and durability. Overall, the project signifies the significance of continuous
innovation and collaboration among engineers and researchers to meet the evolving
demands of industrial power transmission systems.

Leonardo: In conclusion, the integrative project marks a significant step towards

understanding the complexities involved in gearbox development for industrial applications.
The successful implementation of acrylic gears using a laser cutter demonstrates the potential
for cost-effective and accessible manufacturing solutions. While the project encountered
challenges with the limitations of acrylic gears in high-power transmission, it also highlights
the importance of considering material properties and manufacturing processes in gear
design. The use of CAD and CAM tools showcased the power of digital technologies in
streamlining the design and manufacturing workflow. Moving forward, this project serves as a
valuable learning experience, paving the way for further exploration of innovative materials,
advanced machining techniques, and improved gear designs to achieve optimal performance
and reliability in industrial gearboxes. The lessons learned and the interdisciplinary approach
adopted in this project will undoubtedly contribute to advancements in the field of mechanical
engineering and gear system optimization.

Josue: In conclusion, the integrative project has demonstrated the ingenuity and potential of
combining mechanical engineering principles, advanced materials, and computer-aided
design techniques to develop a gearbox suitable for industrial applications. The successful
use of a laser cutter to fabricate acrylic gears represents an innovative approach to
manufacturing, offering cost-effective alternatives for gear production. While the project
encountered challenges related to the limitations of acrylic gears in high-power transmission,
it underscores the importance of material selection and the need for continuous improvement
in gear design. The integration of CAD and CAM tools showcased the power of modern digital
technologies in enhancing design precision and manufacturing efficiency. This project opens
up new avenues for exploration, encouraging further research in materials science, gear
manufacturing processes, and gear system optimization. By fostering interdisciplinary
collaboration and creative problem-solving, this project serves as a stepping stone towards
developing more reliable, efficient, and adaptable gear systems that drive advancements in
various industries.
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https://solid-bi.es/solidworks/

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