In the NAME OF ALLAH, the Most Beneficent, Most

Merciful1

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Manufacturing process labME-304L

•Mini project

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Group members

Fawad khan Irfanullah

Nauman khan Shehryar ishaque

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Project title Designing a gear box

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Overview of the presentation

• Objectives• Introduction• Components of the assembly• Machine used and operations performed• Calculations• Results and conclusions

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Objectives

• To hand over experience of the machines present in the lab.

• To apply the theory of manufacturing process and other subjects.

• To be aware of the various manufacturing processes.

• To get greater torque and smaller speed.• To get smaller torque and greater speed.

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Introduction

Gear box

Combination of gears, to produce low or high speed output.

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Components of the assembly(gear box)

Following are the components of gear box.• Spur gears• Shafts• Bearings• Wooden square boxes• Square housing of wood• Handle • Outer casing of wood

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Machines used

Metal Lathe machine

Drilling machine

Milling machine

Wooden drill machine

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Process involved

• Casting:-4 discs of Aluminum of different dimensions and also of two shafts.

• Facing:-Facing of all the discs and shafts by lathe machine.

• Turning:-Turning of the shafts and discs by lathe machine.

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Continued……..

• Drilling:-In order to fix the disc on the shaft, holes were required which were drilled using a drill machine.

• Boring:-For enlarging the diameter of the discs we carried out boring, to ensure a tight fit of discs and shafts.

• Milling:-Milling machine was used for making teeth on the discs(gear teeth….)

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Continued……

• Tapping Done for making internal threads in collars.• Cutting Cutting of bolts was also done.• Filing filing was done for adjusting the shaft dia

to the bearing.

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Calculation carried out

As a result of finishing the diameter of the discs was brought to

• Disc 1: 104 mm• Disc 2: 88 mm• Disc 3: 62 mm• Disc 4: 46 mm

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Calculation for number of teeth

Formula used for calculating number of teethN=(D/m)-2

m= module =2Disc 1: N=50Disc 2: N=42Disc 3: N=29Disc 4: N=21

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Cutter used

• Cutter # 4,5,5,6 are used for disc 1,2,3,4 respectively having module ratio same i.e. 2.

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Preparation of outer casing and supports

• Making of wooden box for the motion of shaft and bearing.

• Making of flat square housing for inserting the bearings so that the bearing becomes tight.

• Making of outer casing from wood, one base and two stands

• Making of holes and a slot in stands to support shafts.

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Assembling

• We mount discs 1,3 and 4 on shaft A by bolts.

• The other disc # 2 mount on 2nd shaft B.• Insert all the bearing in the correct holes.• Shaft B is the input shaft and shaft A is

output shaft.• Gear 2 will mesh with gears 1,3 and 4 and

giving the respective speed ratio.

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Assembly

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Formula used for calculating the speed ratio

• Mv=no of teeth on driver gear /no of teeth on driven gear

also

Mv=nout/ninput

Where n= speed (rpm)

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Calculation for outputs

• When gear 2 mesh with gear 1, for one rotation of shaft B, shaft A

rotates 0.84 times.• When gear 2 mesh with gear 3, for one rotation of shaft B, shaft A

rotates 1.44 times.• When gear 2mesh with gear 4, for one rotation of shaft B, shaft A

rotates 2 times.

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procedure• The bearings are inserted in shaft B and

then bearings are also inserted into the flat wooden plates where it becomes tight.

• The flat wooden plates can move forward and backward in the boxes for changing the gears.

• The boxes used here to support the bearings in each side.

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Procedure(contd)

• The slot in the stands is used for the left and rightward motion of the shaft B for meshing with the other gears

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Results and conclusion

• The results we obtain from this project are.• We can get three different speeds at output

shaft by just changing the meshing of input gear with the output gears.

• The overall result we get from this mini project is that it is very necessary for a Mechanical Engineer to have hand on experience on these various types of machines.

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Practical applications…

• Automobiles • Most machines • (lathe machine etc)

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Any Question…

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