TYPES OF GEARSSPUR, INTERNAL

Name-ShubhamINVOLUTE
Dongarwar BT13MEC020
Abhijeet Choukade
BT13MEC017

PROBLEM STATEMENT
To manufacture gears according to the
application specified:
Type of Gears: Spur ,Internal spur with
involute profile
Gear Material: Ductile cast Iron
Application :
system

Tractor planetary gear

Planetary Gear System

Material-Ductile Cast
Iron
Overview of cast iron Iron with 1.7 to 4.5% carbon and 0.5 to 3% silicon
Lower melting point and more fluid than steel (better
castability)
Low cost material usually produced by sand casting
A wide range of properties, depending on composition
& cooling rate

Strength
Hardness
Ductility
Thermal conductivity
Damping capacity

Properties of Ductile cast

Mechanical and
ironPhysical Properties
Brinell Hardness Number

197-255

Density

7.1to7.2g/cm3(440to450lb/f
t3)

Elastic (Young's, Tensile)

Modulus

160to180GPa(23to26x
106psi)

Elongation at Break

3to24%

Fracture Toughness

14to30MPa-m1/2

Shear Strength

360to875MPa(52to127x
103psi)

Strength to Weight Ratio

58to136kN-m/kg

Tensile Strength: Ultimate (UTS) 410to830MPa(59to120x

103psi)
Tensile Strength: Yield (Proof)

280to620MPa(41to90x
103psi)

Thermal Conductivity

31to36W/m-K

Chemical Properties
Carbon

3.2 to 3.60%

Silicon

2.2 to 2.8%

Manganese

0.1 to 0.5%

Magnesium

0.03 to 0.04%

Phosphorus

0.005 to 0.04%

Sulfur
Copper

0.005 to 0.02%
<0.40%

Elements such as copper or tin may be added

to increase tensile and yield strength while
simultaneously reducing ductility. Improved
corrosion resistance can be achieved by
replacing 15% to 30% of the iron in the alloy
with varying amounts of nickel, copper, or
chromium.

Size and Weight of

Gears
Type
Diameter Weight(K
Size(Cm)

g)

Spur Gear

15

Internal
Spur

35

Heat Treatment
Austempering
Used to achieve Austempered Ductile Iron,
requires two stages. Stage 1: heating to and
holding at 900C. Stage 2: quenching and
isothermally holding at the required
austempering temperature, usually in a salt bath.

Advantages
1.
2.
3.
4.
5.
6.
7.

Less Distortion
Higher Strength
Higher Toughness
Less Noise
Better Wear Resistance
Lighter Components
Lower Component Cost.

Gear Manufacturing
Process
1. Spur Gear
- Hobbing
- Grinding
- Drilling
2. Internal Spur Gear
-Hobbing
-Grinding

Gear Manufacturing
Process
HobbingIt is a special form of tooling and
manufacturing that cuts tooth type geometries. It is
the major industrial process for cutting (as opposed to
grinding) spur gears of involute form. It forms the gear
by rotating the gear blank on a spindle and the cutter
on a different spindle at the same time.

GrindingA gear
cuttingmethodinwhichgearsareshapedbyformedgr
inding
wheelsandbygeneration;primarilyafinishing
operation. It can produce very fine finishing and very
accurate dimensions. It is generally used for mass
production.

Machines to be used
Manufacturing:
Hobbing Machine
Grinding Machine
Drilling Machine

Material Handling
Chain Conveyers

Storage and Retrieval

Pallet Rack system

Robotic AGV

FMS

Assumptions
1

Maximum production
rate :80 pieces per Day

No of shifts per day : 2

Working hours per day :

16

Mean transport time :

2min

SERVERS PER STATION

STATION

MACHINING

SERVERS

LOAD/UNLOAD

HOBBING

Drilling

HEAT TREATMENT

GRINDING

INSPECTION

PART HANDLING

Operations to be performed
PART (j)

Spur

Internal Spur

PART MIX

0.6

0.4

OPERATION

DESCRIPTI
ON

STATION

TIME(Tijk)
Min

FREQUENC
Y

Load

Hobbing

35

Drilling

15

Heat
Treatment

20

Grinding

10

Inspection

10

0.5

Unload

Load

Hobbing

40

Heat
Treatment

25

Grinding

12

Inspection

10

0.6

Unload

Loop Layout Of FMS

Formulae
Work Load at each Station=Wli=
tijk*fijk*pj
Bottleneck Station = max(WLi/Si)
Rp* = (No. of servers on bottleneck
station)/(Work load on bottleneck
station)
Production Rate , Rp= Pj*Rp*

Determination of Bottleneck
Station
STATION

WLi (min)

Si

Wli/Si

37

22

11

10.8

10.8

10

10

12.33

10.28

10.28

Max(WLi/Si)= 12.33
Hence, the station, i.e. Hobbing is the
bottleneck Station of the FMS.

Production Rates of Each

Part

Rp= (No. of servers on bottleneck station)/(Work

Therefore, Rp*= 0.0811 piece/min
= 4.866 piece/hr
Rp(Spur Gear)
= 2.9196 piece/hr
Rp(Internal Spur Gear)= 1.9464 piece/hr
Actual production rate=Rp*number of hours available
=4.866*16
=77.856

load on bottleneck station)

Utilisation of Each Station

Utilisation, Ui
=(Wli/Si)*Rp
Hence,
U1=48.66%
U2= 100%
U3=72.99%
U4=89.21%
U5=87.58%
U6=81.1%
U7 =83.37%

Overall Utilisation of System

U= (No of servers * utilization of servers
on stations)/ Total no of servers
U (overall) = 85.21%

THANK
YOU