EMD (22564) MICROPROJECT REPORT

Year: 2021-2022

Prepare list of different types of Gears used in Agriculture

machinery, Sugarcane juice machinery, gear boxes of 2-wheeler
and Similar Machines. Write their specifications and basic
selection.

Prepared by,
OMKAR KOTHARE 19129
YASH NARSALE 19139
HIMANSHU PATIL 19140
ADNAN RAMDUL 19142

Of,
ME-5I (M2 BATCH)
In,
M.H. SABOO SIDDIK POLYTECHNIC, Mumbai.

Under the Guidance of,

Prof. Javed Akhtar sir
HOD, Department of Mechanical Engineering (Aided).

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 Index
I. Gears used in agricultural machinery
II. Gears used in sugarcane machine
III. gearbox of 2-wheeler
IV. Gears used in

I. Gears used in agricultural machinery

Helical Gears is used in Agricultural Machinery.

Helical gears connect parallel shifts but the involute teeth are cut at
an angle to the axis of rotation. Two mating helical gears must have
equal helix angle but opposite hand. They run smoother and more
quietly. They have higher load capacity, are more expensive to
manufacture and create axial thrust.

Helical gears can be used to mesh two shafts that are not parallel and can also be used in a
crossed gear mesh connecting two perpendicular shafts. They have longer and strong teeth.
They can carry heavy load because of the greater surface contact with the teeth. The
efficiency is also reduced because of longer surface contact. The gearing is quieter with less
vibration.

Gear Configuration
They can be manufactured in both right-handed and left-handed configurations with a helix
angle to transmit motion and power between non-intersecting shafts that are parallel or at 90
degrees to each other. For shaft at 90 degrees, the same helix angles are used and the tooth
contact area of the gear is very small. If the angle of gear teeth is correct, they can be
mounted on perpendicular shaft by adjusting the rotating angle by 90 degrees. The inclination
of the teeth generates an axial force. As the angle of inclination increases the axial force also
increases. Thrust bearings can counter these forces.

Applications
These are highly used in transmission because they are quieter even at higher speed and are
durable. The other possible applications of helical gears are in textile industry, blowers,
feeders, rubber and plastic industry, sand mullers, screen, sugar industry, rolling mills, food

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 industry, elevators, conveyors, cutters, clay working machinery, compressors, cane knives
and in oil industry.

Disadvantage
A disadvantage of helical gear is the resultant thrust along the axis of the gear, which needs to
be accommodated by appropriate thrust bearings. This can be overcome by the use of double
helical gears by having teeth with a 'v' shape.
II. GEARS USED IN SUGARCANE MACHINE
Gear is nothing but a toothed wheel which is useful to transmit power from one shaft to another shaft. They
are suitable when two machine parts are nearer to each other. They give exact ratio of transmission of
motion, slip cannot takes place between gears, and they are useful for high torque transmission. In spur gear
teeth is parallel to axis of rotation. Spur gear transmit power from one shaft to another parallel shaft.

Materials for Gears: The gear materials used for the manufacture of gears depend upon the strength
and service conditions like wear and noise etc. The gears maybe manufactured from metallic or non –
metallic materials. The cast iron is widely used for the manufacture of gears due to its good wearing
properties, excellent machine ability and ease of producing complicated shapes by casting method. The non
– metallic materials like wood, rawhide, compressed paper and plastics like Nylon, Acrylic and Polycarbonate
etc. are used for gears, especially for reducing weight and noise.

Theoretical calculations of conventional Cast iron Spur gear: In the present analysis the
maximum torque, allowable stress and tangential load of the spur gear are calculated based on the desired
sugarcane juice machine motor specifications.

Specification of Existing Cast Iron Gear: His typical chemical composition of the cast iron material:
Carbon - 2.5 to 3.7%, Silicon - 1.0 to 3.0%, Manganese - 0.5 to 1.0%, Phosphorus - 0.1 to 0.9% and Sulphur -
0.07 to 0.10%

SPECIFICATIONS OF NYLON AND POLYCARBONATE PLASTIC MATERIALS:

Chemical composition of Nylon:

Its properties are determined by the R and R' groups in the monomers. In nylon 6. 6, R' = 6C and R = 4C
alkanes, but one also has to include the two carboxyl carbons in the dyadic to get the number it donates to
the chain. The majorities of nylons tends to be semi- crystalline and are generally very tough materials with
good thermal and chemical resistance. The different types give a wide range of properties with specific
gravity, melting point and moisture content tending to reduce as the nylon number increases. Nylons can be
used in high temperature environments. Heat stabilized systems allow sustained performance at
temperatures up to 185oC. Chemical composition of Polycarbonate: The main polycarbonate material is

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 produced by the reaction of biphenyl A and phosgene COCl2. The overall reaction can be written as follows:

Polycarbonates received their name because they are polymers containing carbonate groups (–O–(C=O)–
O–). Most polycarbonates of commercial interest are derived from rigid monomers. A balance of useful
features including temperature resistance, impact resistance and optical properties position polycarbonates
between commodity plastics and engineering plastics

Table: 1 Material properties of cast iron, Nylon and Polycarbonate:

Material Property Cast Iron Nylon Polycarbonate

Young’s Modulus 1.65e5 2.1e5 2.75e5

(N/mm 2)
Poisson’s ratio 0.25 0.39 0.38

Density (Kg/mm 7.2e-6 1.13e- 6 1.1e-6

3)
Co-efficient of 1.1 0.15- 0.25 0.31
friction
Ultimate Tensile 320-350 55-83 55-70
strength (Mpa)

Finite Element Analysis of Spur Gear:

Finite element modelling is described as the representation of the geometric model in terms of a finite number of
element and nodes. It is actually a numerical method employed for the solution of structures or a complex region
defining a continuum. Solutions obtained by this method are rarely exact. However, errors in the approximate
solution can be minimized by increasing the number of equations till the desired accuracy obtained. This is an
alternative to analytical methods that are used for getting exact solution of analysis problems. The solution of
general problem by finite element method always follows an orderly step-by-step process. For analysis in ANSYS
10.0. The loading conditions are assumed to be static. The element chosen is solid Brick 8 node45.

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Loads and boundary conditions of the gear

Displacement pattern for Cast iron gear

Stress distribution for Cast iron gear Stress distribution for Polycarbonate spur
gear

Displacement pattern for Nylon gear

Stress distribution for Nylon spur gear

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Displacement pattern for Polycarbonate spur gear

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Results and discussion
From the static analysis by increasing the pressure on the tooth flank surface we observed that the vonmise stresses
and deflection values of the spur gear were increased. And the minimum stress values are obtained for Nylon spur
gear compared with Cast iron and Polycarbonate. According to the study, analysis, results and graphs we
recommend the best plastic material is Nylon and Nylon gears are suitable for the application of sugar cane juice
machine under limited load conditions.

CONCLUSIONS:
To find the suitable design gears with less weight and less cost, corrosion resistance, frictionless also. To design and
manufacture a sugarcane juice for a common people including women. With less cost, self-lubricating neat and clean
hygienic juice. With more material removal of deflection and stress are increased. So for safe operation of my design
is more appropriate under limited load conditions for Nylon gear.

III. GEARBOX OF 2-WHEELER

Two wheelers generally use spur gears instead of helical gears in their transmissions.
Spur Gear

 Easier to manufacture
 No axial forces to deal with
 Produce a characteristic whine at higher speeds
 Less demanding of lubricant
 Can slide in and out of connected gears
BASIS OF SELECTION:
the material type and heat treatment process selected for the gear have a great impact on the internal quality
and service performance of the gear.
In order to improve the load-bearing capacity and prolong the service life of gears, the gears generally need
to undergo proper heat treatment while the materials are reasonably selected. The gear after heat treatment
shall meet the following requirements in performance:
(1) It has higher hardness of tooth surface to improve fatigue resistance and better wear resistance to reduce
tooth surface wear.
(2) The gear center has high mechanical properties and enough toughness, so that the gear can withstand
large impact load.
(3) The hardness of the matched gear should be poor to reduce the possibility of gluing.

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There are many materials suitable for gear manufacturing, such as forged steel, cast steel, cast iron, non-
ferrous metal and non-metallic materials. Various heat treatment methods, such as normalizing, tempering,
surface quenching, carburizing and nitriding, are widely used in gear manufacturing.
According to the load and rotate speed of motorcycle gear, forged steel is mostly used. The following
mainly introduces the selection of motorcycle gear materials and the corresponding heat treatment methods.
Manufacturing materials of motorcycle gears
(1) High quality low carbon steel, such as 20, 08, SPC
(2) High quality medium carbon steel, such as 35, 40, 45
(3) Low alloy steel, such as 15Cr Mo, 20Cr Mo, 20Cr Mn Ti
(4) Medium alloy steel, such as 40Cr, 35Cr Mo
Due to its high strength, toughness and processing performance, medium carbon steel is widely used in the
manufacture of motorcycle gears, of which 40 steel and 45 steel are the most widely used.
Selection principle of motorcycle gear material
(1) Generally, 20, 08 and SPC steel are used as engine starting idler gear and starting sector gear
(2) 15CrMo, 20CrMo and 20CrMnTi steel are generally used for engine gearbox gear and main and
auxiliary shafts
(3) In addition to the above two items, the driven gear, sprocket, starting motor shaft and tachometer gear
with large speed ratio are generally made of 35, 40, 45, 40Cr and 35Cr Mo steel.

III. Bevel Gears: -

Bevel gears are conically-shaped at their tooth-bearing faces, and the axes of the
shafts intersect. They are most often mounted on shafts that are at a 90-degree
angle from one another. They are able to translate one direction of force into
another, with the potential to change direction and operating angles as well. The
uniqueness of bevel gears gives them many advantages, such as the ability to
change operating angles and mechanical advantage.

Bevel Gears used in: - They are not an obscure gear that only sees the light of day every
now and then – the average jane and joe will have used many a machine that works thanks to bevel gears.
Here are some examples of the many applications of bevel gears in everyday machinery:
 
1. Hand drills
Perhaps the most famous use of bevel gears is in hand drills. In fact, if you simply observe a hand drill in
action, you will be able to see the bevel gears at work, changing the vertical rotation of the handle into the
horizontal rotation of the drill. It is a simple process, but one that leads to the success of many other
processes. The bevel gears in hand drills also help to increase the speed of the original rotation, allowing for
hand drills to work with the level of power that they do.
 
2. Cars

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Specifically, bevel gears are used in the differential drives that are found in cars. The differential drive used
in cars is designed to drive a pair of wheels while allowing them to rotate at different speeds. A differential
drive includes at least three bevel gears, working together to transmit speed, power, and rotation.
 
3. Mechanical garage doors
The mechanism in electrical garage doors which allow them to open on command utilize bevel gears – the
gears allow the doors to be rolled up, turned, and opened. The gears are set at a 90-degree angle to one
another, so that when the doors are lifted utilizing vertical force, the gears convert the direction of the force
horizontally, allowing the doors to slide along the ceiling.
 
As you can see, bevel gears have important applications in our daily lives. Without them, basic functions
and machinery that we take for granted will not be able to work.

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