Rapid Prototyping of Gear & Shaft for Transmission Assembly

8/11/2019 Rapid Prototyping of Gear & Shaft for Transmission Assembly

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DESIGN AND RAPID PROTOTYPING OF

SPUR GEAR AND SHAFT FORTRANSMISSION ASSEMBLY

byWadate Pramod R.

M. E. (Production) Sem IV

Guide

Dr. R. M. Warkhedkar


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Acknowledgements

Varroc Engineering Pvt Ltd, Aurangabad.

DesignTech Systems Pvt Ltd, Pune.


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INDEX

Introductiono Objectiveo Literature Survey

System Development Performance Analysis

Conclusions References


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INTRODUCTION Objective

Design, analysis and Rapid Prototyping of gear and shaft fortransmission assembly for Varroc Engg. Pvt. Ltd.

NecessityCycle time of product is very high in traditional method. This canbe reduced by building R.P. model.

Design

Rapid PrototypingAnalysis


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Product development and rapid prototyping

In recent years, the competition in all fields of industry has intensifiedtremendously. This intense competition requires the time needed for a productto reach a customer to be decreased as much as possible.

Today, in the harsh competition environment a product gets older in just a fewmonths after its launching. Due to this rate of depreciation of products is veryhigh. This competition results in reduced product development cycle.

For fulfilling very short product development time, traditional productdevelopment techniques were infeasible and lengthy also. To overcome thisshortcoming virtual model and analysis along with rapid prototyping techniquesare used widely in product development.


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3Dimension uPrinting Machine

Literature Survey

3Dimension Sink

CAD and Geometric Modeling [6],[7],[10],[13]

1. Surface Models2. Solid Models

Rapid Prototyping [20-27]


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Working Principle of 3 Dimensional Printer

3 Dimensional Printing works on Fused Deposition Modeling (FDM) principle.


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3D SolidModeling

DataPreparation Part Building Pass

Reject

Redesign

Process Flow


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Basic Principle of Rapid Prototyping .

1. Creation of the CAD model of the design.2. Conversion of the CAD model to STL format.3. Slicing the STL file into thin cross-sectional layers.4. Layer by layer construction.5. Cleaning and finishing the model


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CAD Solid ModelSolid Model or Closed Surface Model is required


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Software generates the object description

File consists of the X, Y, Z coordinates of the threevertices of each surface triangle, with an index todescribe the orientation of the surface normal

Support generation to hold overhung surfaces duringbuild


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Slicing the file Series of closely spaced horizontal planes are mathematically

passed through the .stl file

Generate a .sli file : a series of closely spaced 2D cross -sections of the 3D object

Typical Z thickness 0.154 mm


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Final Build File Part sliced

Supports sliced RP technology parameters set

layer thickness, scan speed,... Send file to RP machine


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Fabrication of Part


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Post-processing

Removal of part from platform Removal of supports from part Cleaning of part

Finishing part


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Product Specifications 3 Dimension uPrint Model material:

ABS plus in ivory

Build size:203 x 152 x 152 mm (8 x 6 x 6 in)

Layer thickness:

0.254 mm (0.010 in) deposited model and support material Size and weight:

uPrint printer and one material bay:635(w) x 660(d) x 800(h) mm (25 x 26 x 31.5 in) 76 kg

uPrint printer and two material bays:635(w) x 660(d) x 953(h) mm (25 x 26 x 37.5 in) 94 kg

Power requirements: 100-127 VAC 50/60 Hz, minimum 15A dedicated circuit, or220-240 VAC 50/60 Hz, minimum 7A dedicated circuit

Special facility requirements: None


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System Development Part Drawing

Stresses on Gear


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Lewis EquationF

t =

w.b.p

cy

=

w.b..m.y

Dynamic Load

FD = FT + FI

Static LoadFs = eb..m.y

Wear LoadFw = Dp.b.K.Q


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Design and Developing solid CAD model

Second Drive Gear


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Third & Fourth Driving Gear


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Fifth Drive Gear


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Sixth Drive Gear


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Input Shaft


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Building R. P. model

The rapid prototype model has been prepared with the help of

uPRINT 3 Dimensional printing machine. It is a layer by layer manufacturing process working as FDM

(Fused Deposition Modeling). This technique is much morebeneficial in comparison with other techniques.

3 Dimensional printing is based on CatalystEX software. Thebasic requirement of this software is, the prepared CAD modelfile should be in the form of .STL for printing. The CAD modelloaded into uPRINT 3Dimension machine for preparing

prototype.


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Window of CatalystEx Software


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Loading of CAD model


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General Feature


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Orientation Feature


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Pack Feature


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Printer Status Feature


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Printer Service Feature


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Performance Analysis Performance analysis parts consist of analysis of gear, shaft and

prepared prototype model. Gear analysis is made for tooth failure (calculating VonMises)

with the help of Ansys software. Hypermesh software is used for shaft analysis to calculate the

VonMises Stress at maximum load condition. As the Hypermeshis best mesher and Nastran is best solver.


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Second Drive Gear Analysis


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Third & Fourth Drive Gear Analysis


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Fifth Drive Fear Analysis


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f


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Input Shaft Analysis

The analysis of shaft is done for VonMises stress and for displacementat maximum load condition. Hypermesh is used for analysis of shaft. In

Hypermesh there is a list of solver available such as Radioss,Optistruct, LsDyna, Nastran, etc. Nastran is best solver in Hypermeshenvironment.

The basic procedure used for analysis is:

1. Importing .iges file as a goeometry.2. Auto Geometry cleanup.

3. Meshing the geometry.4. Defining Material Collector.

5. Boundary Condition and Solver.a. Creating Constraints

b. Defining Load Collectorc. Applying Forces

d. Importing values of Youngs Modulus and Modulus of Elasticity.


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Meshed model


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VonMises stress for shaft at maximum load condition


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Displacement of Shaft

R P Model


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R.P. Model

Second Drive Gear


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Third & Fourth Drive Gear


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Fifth Drive Gear


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Sixth Drive Gear


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Input Shaft

Conclusions


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Conclusions

The development of engineering product can be prepared at very precise accuracy.

The product development time can be reduced by 3 D printingtechniques.

Three dimensional printers are relatively new in the market andare attracting wide attention due to their varied applications.

Applications


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Applications Proof of Concept: A tool for creating models early in the

design process, 3D Printing is a both a faster and moreaffordable alternative to Rapid Prototyping technology.

Functional Testing: The gear and shaft prototype can beassembled. It can be to test form, fit and function.

Product Cost Reduction: R.P. allows reducing costs, with

better communication, collaboration and designing verificationthroughout the process. Product Confidentiality: A Dimension 3D Printer ensures that

the designs are considering remains secure inside company .

Product Mockups: It saves a lot of time and money using theirDimension 3D printers for creating product mockups.

References


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References1. L. Kapelevich, Geometry and Design of Involute Spur Gears with Asymmetric

Teeth , Mechanism and Machine Theory, 35 (2000), pp. 117 -130.2. X. Liu, G. Dodds, J. McCartney, B.K. Hinds, Virtual Design Works, Designing 3d

Cad Model Via Haptic Interaction Computer Aided Design , Volume 36, Issue 12 ,October 2004 , pp. 1129-1140

3. Drago, R. J. (1992), Gear Types and Nomenclature (D. P. Townsend, editor).Duddleys Gear Handbook, 2 nd Edition, McGraw Hill Inc., New York, pp 2.1-2.19.

4. Machinerys Handbook 26 th edition, Gears and Gear Designwikipedia.org/wiki/Computer- Aided Design pp. 1995-2125

5. Duddley, W.D. (1992). Gear Tooth Design , Duddleys Gear Handbook, SecondEdition, McGraw Hill Inc., New York, pp 4.1- 4.93.

6. Roy, S., Pohit, G. and Saha, K.N., Computer Aided Design of Spur Gear ,Proceedings of 20 th AIMTDR Conference, BIT Mesra, Ranchi, India, 13-15 Dec.,2003, pp. 137-145

7. Balyliss, G. M., Bowlyer, A., Talyor, R. I. and Willis, P.G., Theoretic SolidModeling Techniques and Application Using the Virtual Manufacturing ;Proceedings of CSG-94, 1994, pp. 314-320.

8 J H Song YT Im Development Of Computer Aided Design System of Cold


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8. J.H. Song, Y.T. Im, Development Of Computer Aided Design System of ColdForward Extrusion of A Spur Gear Journal of Materials Processing Technology ,Volumes 153-154 , 10 November 2004 , pp. 821-828

9. Tucker,A. I., The Gear Design Process , ASME Paper 80 -c2/DET-13, 1980

10. Liang Xu, Min-xu Lin, Jian-qiao Li, Zhao- liang Wang, B. Chirende, ThreeDimensional Geometric Modeling of Wild Boar Head By Reverse EngineeringTechnology, Journal of Bionic Engineering, Volume 5, Issue 1 , March 2008 ,pp. 85-90.

11. Ali Raad Hassan, Transient Stress Analysis in Medium Modules Spur Gear Tooth

by Using of Mode Super Position Technique , International Conference ofMechanical Engineering, Tokyo, Japan, 27-29 May 2009, World Academy ofScience, Engineering and Technology, Volume 53, 2009, pp. 49-56

12. R.S.Khurmi, J.K. Gupta, Machine Design, 2003, pp. 933-94113. Arangarasan, R. and Gadh; R., Geometric Modeling and Collaborative Design in

Multimodel , Virtual Environment; Proceedings of ASME, IDETC/CIE Conference,Sept. 10-13, 2000, pp. 46-52.

14. A. L. Kapelevich, Y. V. Shekhtman, Direct Gear Design: Bending StressMinimization , Gear Technology, September/October 2003, pp. 44 - 47.

15. G. Madhusudan, C.R. Vijayasimha, Approach to Spur Gear Design, Computer- Aided Design , Volume 19, Issue 10 , December 1987 , pp. 555-559.

16 V Senthil Kumar D V Muni G Muthuveerappan Optimization of Asymmetric


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16. V. Senthil Kumar, D.V. Muni, G. Muthuveerappan, Optimization of AsymmetricSpur Gear Drives to improve the Bending Load Capacity, Mechanism andMachine Theory , Volume 43, Issue 7 , July 2008 , pp. 829-858.

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Environment ; CIRP Annals, 42: 147-150,1993, pp. 147-150.18. You-Min Huang, Hsiang- Yao Lan, CAD/CAM/CAE integration for increasing the

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19. www.dimensionprinting.com

20. www.zcorp.com21. www.altair.com22. www.nastran.com23. http://3dsystems.com

24. http://www.plm.automation.siemens.com25. http://www.stratasys.com26. www.ansys.com27. www.rapidprototyping processes.html

28. www.gearseds.com
http://www.nastran.com/http://www.nastran.com/http://www.nastran.com/http://www.nastran.com/


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28. www.gearseds.com29. www.prototypezonr.com30. N. Hopkinson, P. Dickens, Rapid prototyping for Direct Manufacture , Rapid

Prototyping Journal , Volume 7 Number 4, Bradford: MCB University Press 2001,

pp. 197 202.31. Ali Raad Hassan, Contact Stress Analysis of Spur Gear Teeth Pair , World

Academy of Science, Engineering and Technology, 2009, pp. 210-21432. Chen, Y.H; Song, Y. (2001). The Development of A Layer Based Machining

System , Computer -Aided Design, pp. 331-342.


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Rapid Prototyping of Gear & Shaft for Transmission Assembly