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    PROJECT1

    Uploaded by

    Lương Hồng Phúc
    mini project of mechanic introduction

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    PROJECT1

    Uploaded by

    Lương Hồng Phúc
    14 views15 pages
    mini project of mechanic introduction

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    © © All Rights Reserved

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    PDF, TXT or read online from Scribd

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    mini project of mechanic introduction

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    14 views15 pages

    PROJECT1

    Uploaded by

    Lương Hồng Phúc
    mini project of mechanic introduction

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 15

    PROJECT 1: Gear 1

    Name: Lương Hồng Phúc

    Student ID: 20237041


    Part 1: INTRODUCTION
    Definition: Gears are one of the most fundamental mechanical devices in the

    world. Gears are particularly useful for the transferral and translation of

    rotary motion, and are able to manipulate speed, torque, and rotational

    axis within a given machine.

    Classification:

    -there are many kinds of gear: spur gear, helical gear, internal gear,

    bevel gear, miter gear, screw gear, worm gear,….


    My product is called keyway spur gear

    Characteristics:

     Easy to manufacture

     There are no axial force

     Relatively easy to produce high-quality gears

     The most common type of gear

     There is a slot cut into its bore that aligns with a corresponding slot

    on the shaft

    Application: gear pump


    Dimensions:

    Face width 50mm


    Inner diameter 55mm
    Outer diameter 140mm
    Number of teeth 30
    Clearance 10mm
    Width of space 3.7mm
    Width of keyway slot 10mm
    Length of keyway slot 20mm
    Part 2: MATERIALS
    In material, there are METAL, PLASTICS, CERAMICS, COMPOSITES.

    For the gear pump, the gear is sustained high pressure and torque. To adapt

    these requirements, I need a high strength material, so I choose HIGH

    CARBON STEEL.

    =>AISI 52100

     Physical properties:

    Density 7.81 g/cm3


    Specific heat 460 J/(kg·K)
    Melting point 1424°C
    Thermal expansion 11.9 µm/m°C
    Thermal conductivity 46.6 W/mK

    Phase diagram of Fe-C

    system

     Mechanical properties:

    Hardness 848HV
    Tensile Strength 700 MPa
    Shear modulus 80 GPa
    Poisson's ratio 0.28
    Yield Strength 1,700 MPa
     Chemical composition:

    PART 3: manufacturing

    This picture show the overview of manufacturing a gear.

    These are 7 steps to

    manufacturing :
    Step 1: Material Preparation

     Material Selection: AISI 52100 high-carbon steel is selected for its

    excellent wear resistance and high tensile strength.

     Procurement: Steel billets or bars are sourced in bulk to optimize cost.


     Cutting: The steel is cut into cylindrical blanks with dimensions

    slightly larger than the final gear (outer diameter: ~145mm, inner

    diameter: ~60mm, face width: ~52mm) to account for machining

    allowances.

    Step 2: Forging

     Purpose: To improve the mechanical properties by refining the

    material’s grain structure, increasing strength and toughness.

     Process:

    1. The blank is heated in a furnace to approximately 1200°C,

    beyond the recrystallization temperature of steel.

    2. Using a closed-die forging press, the blank is shaped into a

    near-net form of the gear, focusing on the outer diameter and

    hub.

    3. After forging, the part is cooled gradually to relieve internal

    stresses.

     Inspection: Ultrasonic testing ensures the forged blank is free from

    internal defects.

    Step 3: Machining

     Purpose: To achieve precise dimensions for the blank, ensuring it is

    ready for gear cutting.


     Processes:

    1. Turning:

     A CNC lathe is used to turn the outer diameter to

    140mm and the inner bore to 55mm with tight

    tolerances.

    2. Boring:

     The inner bore is refined, and the hub dimensions are

    finalized.

    3. Keyway Slot Machining:

     A broaching machine cuts the keyway slot (10mm wide,

    20mm long) in the bore to align with the shaft.

     Inspection: A micrometer and gauges verify the dimensions.

    Step 4: Gear Tooth Creation

     Method: Hobbing.

     Process:

    1. A hob cutter is set up on a hobbing machine. The blank is

    mounted, and the number of teeth (30) is programmed into

    the machine.

    2. The cutter rotates in synchronization with the blank, removing

    material incrementally to form precise teeth profiles.


    3. The space width between teeth (3.7mm) and the involute profile

    are maintained throughout.

     Cooling: Cutting fluids are used during the process to prevent

    overheating and ensure smooth cutting.

     Inspection:A profile projector or a gear measurement machine checks

    the tooth geometry for uniformity and accuracy.

    Step 5: Finishing Operations

     Purpose: To improve the gear's precision, reduce friction, and enhance

    durability.

     Processes:

    1.Grinding:

    The gear teeth are ground using a CNC gear grinding machine

    to achieve a smooth surface finish and precise tooth geometry.

    2.Polishing:

    The gear is polished to further reduce friction and ensure better

    meshing with mating gears.

    3. Deburring:

    Any burrs or sharp edges left from previous processes are

    removed manually or using a deburring machine.

    Step 6: Quality Control


     Purpose: Ensuring that the manufactured gear meets the design

    specifications and application requirements.

     Tests:

    1.Dimensional Accuracy: Checked using a Coordinate Measuring

    Machine (CMM) to ensure compliance with design tolerances.

    2.Tooth Profile: Inspected using a gear tester to validate the

    involute profile and spacing.

    3.Surface Finish: Measured using a profilometer to verify a

    smooth finish.

    4.Hardness Testing: Verifies that the gear has achieved the

    desired surface hardness and core toughness.

    Step 7: Assembly Preparation

     Cleaning: The gear is cleaned using ultrasonic or chemical cleaning

    methods to remove residues.

     Coating: An anti-corrosion coating is applied to protect the gear

    during storage and transportation.

     Final Inspection: Visual and functional checks ensure the gear is ready

    for assembly.

    PART 4: Heat treatment


     PURPOSE:

    - Increased Surface Hardness: Protects against wear and surface

    fatigue.

    - harden Core: Provides strength and flexibility to absorb shocks.


    - Enhanced Fatigue Resistance: Prolongs gear lifespan under cyclic

    loads.

     PROCESS:

    I, Carburizing
    1. The gear is placed in a carbon-rich atmosphere (e.g., methane

    gas) at high temperatures (900–950°C).

    2. Carbon atoms diffuse into the surface, forming a hardened layer

    (case depth typically 0.5–2mm).

    =>increase surface hardness

    II, Quenching
    1. The carburized gear is heated to austenitizing temperature

    (~850–900°C).

    2. The gear is cooled quickly in a medium such as oil, water, or

    polymer.

    => hardening the surface

    III, Tempering
    1. The quenched gear is reheated to a moderate temperature

    (~150–300°C).

    2. Held at this temperature for a specified duration (1–2 hours),

    then cooled.

    => reduce brittleness from quenching and improve toughness


    DIAGRAM OF HEAT

    TREATMENT

    PART 5: Conclusion
    With the presentation above, we can imagine the complication of

    manufacturing a gear. But after calculating, manufacturing we will get an

    excellent gear that we need in machine.

    I have some comments of advantages and disadvantages :

    -Advantage:

    +, High strength and quality gear.

    +, high precision.
    +, long toughness.

    +, product can work in hard conditions.

    -Disadvantage:

    +, high cost to manufacture

    +, require morden machines

    +, hard to manufacture

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