A MINI PROJECT ON

FABRICATION OF PROTOTYPE GEAR TRAIN USING CO2 LASER CUTTING

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
BY
S.RAKESH ( 21WJ5A0381 )
O.ANUJA ( 21WJ5A0364 )
SK.WAZEED ( 21WJ5A0378 )
Under the Guidance of
Mr . HAZI BASHA(Asst.prof)

Department Of Mechanical Engineering

GURU NANAK INSTITUTIONS TECHNICAL CAMPUS,RANGAREDDY(DIST),HYDERABAD
CONTENTS
• ABSTRACT
• OBJECTIVE
• INTRODUCTION
• LITERATURE REVIEW
• METHODOLOGY
• ADVANTAGES
• DISADVANTAGES
• RDWORKS SOFTWARE
• APPLICATIONS
• REFERENCE
 ABSTRACT

This project revolves around the conceptualization, design, and analysis of a gear train system tailored for a specific
application. Gear trains serve as fundamental components in various mechanical systems, enabling the transmission of
power and torque between rotating shafts while altering speed and direction.

This project centers on the thorough investigation, optimization, and analysis of a gear train system a crucial
mechanical arrangement responsible for transmitting power, adjusting speed, and altering torque between rotating
shafts in various engineering applications. The objective of this study is to achieve maximum efficiency and
performance while minimizing energy losses and enhancing the reliability of the gear train system.
 OBJECTIVE

 To change the speed of rotation

 To increase or decrease torque
 To transmit power
 To maintain Constant Speed
 Load Distribution
 Controlled Motion
Introduction

• In the realm of gear train fabrication, leveraging

CO2 laser cutting technology offers precision and
efficiency. This advanced method utilizes a focused
CO2 laser beam to precisely cut through materials
with minimal heat-affected zones. In the process of
creating a prototype for a gear train, CO2 laser
cutting proves instrumental in achieving intricate
designs and maintaining tight tolerances. This
introduction sets the stage for exploring how this
cutting-edge technology enhances the fabrication
process, ensuring a reliable and accurate prototype
for a robust gear train system.
 A gear train is a collection of gear wheels that transmit motion from one shaft to another. Ordinary
gear trains consist of simple and compound gear trains. The epicyclic gear trains, which allow
relative motion between gear axes, are the other types of gear trains. The gear trains are necessary
when a significant reduction in velocity or mechanical advantage is desired. The distance between
two shafts is not excessively long but not short enough to allow for the use of a single big gear.
When a particular velocity ratio is desired.
• Types of Gear Trains
Depending on how the wheels are arranged, there are several different types of gear trains.
Below we have mentioned four types of gear trains where the axes of the shafts on which the gears
are mounted are fixed relative to each other in the first three types of gear trains. Knowing the types
of gear trains is helpful in designing gears as well. It is essential to know gear terminologies as well
before going further. The axes of the shafts on which the gears are mounted may, however, move
relative to a fixed axis in epicyclic gear trains.
Simple gear Compound gear Reverted gear
Types of Gear trains
• Simple Gear Train: In a simple gear train, gears are connected in series along parallel shafts,
providing a basic means of speed and torque conversion.
• Compound Gear Train: Compound gear trains combine multiple gears on a common shaft to
achieve a wider range of speed and torque ratios, enhancing versatility.
• Reverted Gear Train: A reverted gear train features gears in a compound arrangement where the
axes of the first and last gears coincide, creating a unique mechanical configuration.
• Epicyclic Gear Train: Epicyclic gear trains involve one gear revolving around another, resulting
in complex motion patterns. They are used in various applications, including planetary gear
systems.
• Differential Gear Train: Differential gear trains are found in vehicles and machinery to distribute
power to multiple outputs while allowing them to rotate at different speeds, as in the case of a
vehicle’s differential.
 LITERATURE REVIEW

A. Kahraman, H. Ligata, A. Singh has presented a paper on “Influence of ring rim thickness on
planetary gear set behaviour”. The intension of the paper is to estimate the contribution of ring gear
rim thickness on the rim deflection and root and hoop stresses. It can be noted that rim thickness is
an important factor it should considered while designing of gear train because of it can play major
role on planet load sharing of gear sets.
A. Kahraman and H. Ding has developed a methodology to envisage surface wear of planetary
gears under dynamic condition. The focus of the study is to find out wear depths at ring planet
meshes and the sun planet meshes. The method contains combination of tensional dynamic model
and surface wear model from that to foretell the contribution of worn surface profiles motion
transmission error and contribution of dynamic tooth force on wear model. The internal gear pair
wear is considered because of the wear rate of ring planet meshes smaller than the wear depth or rate
of sun planet meshes in order to reduce wear cycles. The dynamic forces and harmonic amplitude
contributes on surface wear in both off-resonance and resonance condition. The wear depth is high in
resonance region because of increment of dynamic mesh load.
 METHODOLOGY

 Design Preparation

 Material Selection

 RDWorks Setup

 Laser Cutting Process

 Laser Cutting the Gear Train

 Post-Processing

 Quality Check
 Laser Cutting Parameters on Various Materials
Maximum
Typical Typical Minimum
Material Heat-Affected
Material Laser Power Cutting Speed Kerf Width Applications
Thickness Zone (mm)
(Watts) (IPM) (mm)
(mm)

Furniture making, woodworking, signage,

Wood 60-150 50-200 0.1-0.2 20 0.1-0.5
crafts

Acrylic 40-80 100-300 0.1-0.2 20 0.1-0.3 Signage, displays, enclosures, crafts

Plastics 50-100 50-200 0.1-0.2 10 0.1-0.5 Packaging, electronics, automotive parts

Metals 200-1000 5-50 0.1-0.5 5 0.1-1.0 Metal fabrication, electronics, aerospace

Leather 40-80 50-200 0.1-0.2 5 0.1-0.3 Footwear, fashion, accessories

Fabric 40-60 100-300 0.1-0.2 2 0.1-0.3 Apparel, textiles, industrial applications

Paper 20-40 100-500 0.1-0.2 1 0.1-0.2 Packaging, crafts, prototyping

 ADVANTAGES

• Power Transmission
• Speed and Torque Modification
• Directional Control
• Load Distribution
• Mechanical Advantage
• Automation and Control
 DISADVANTAGES

• They are not suitable for transmitting motion over a large distance.
• Due to the engagement of toothed wheel of gears, some part of machine may get permanently
damaged in case of excessive loading.
• They have no flexibility.
• Gear operation is noisy.
RDWorks Software
RDWorks is a professional laser engraving and cutting software developed by Ruida Technology Co., Ltd. It is
widely used in various industries, including laser engraving, laser cutting, and laser marking. RDWorks is a
powerful and versatile software that supports a wide range of laser machines and file formats. It is also easy to
use and learn, making it a popular choice for both beginners and experienced users.
Uploading the drawn gear images in RDWorks software
Load file from RDWorks software to the CO2 Laser
Cutting Machine
Based on the material size and give the speed and
cutting parameters to the machine
Cutting parts images in CO2 laser Cutting Machine
After assembling all the cutting parts you get
the gear train same as shown in figure
 APPLICATIONS

o Automotive transmissions
o Industrial machinery
o Clock mechanisms
o Robotics
o Wind turbines
o Aerospace
o Printing industries
 CONCLUSION

• In conclusion, the gear train project crafted utilizing CO2 laser cutting technology presented both successes
and areas for further refinement. The methodology encompassed the design creation, material selection,
RDWorks software utilization, laser cutting process, post-processing, and quality assessment.

• In summary, the CO2 laser cutting technique demonstrated its capability in fabricating a functional gear train
with commendable precision and quality. However, continuous refinement in settings, material selection, and
design intricacy could further elevate the project's outcomes and expand its applicability across various
industries.

• This project not only showcased the potential of CO2 laser cutting in gear manufacturing but also highlighted
avenues for future enhancements and developments in the field of precision engineering.
 REFERENCE

• Handbook of Laser Technology and Applications: Volume V: Laser Systems and Applications" by Colin E.
Webb and Helge H. Rubins

• Industrial Laser Handbook" by Peter Krausz and Wolfgang König

• Laser Cutting of Materials" by J. Paulo Davim

• Fundamentals of Gear Design" by W. Dudley

• Theory of Gear Trains" by W. M. Hamilton

THANK YOU