University of Wah

Department of Mechanical Engineering

UNIVERSITY OF WAH
WAH ENGINEERING COLLEGE
Mechanical Engineering Department
Quiz # 02
Course Title: Technical Writing Course Code: ME-314
Semester & Section: spring Course Teacher: Lecturer Humaira
Nasir
Total Marks: 10 Submission Date: 31 March, 2021
Student Name Khezar Hayat Reg No.uw-18-me-bsc-020__

Date:

Course Learning Program Learning Learning Domain

Outcome Outcome

CLO-1 PLO-10 C6

CLO-3 PLO-12 A4

Q1. Formulate the editing and evaluation in the given reports where it is required.

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Department of Mechanical Engineering

OPEN ENDED LAB

Contents

Objective: 2

Theory: 3

Introduction: 3

Different Types of Gears and Uses:- 3

Spur Gears:- 3

Helical Gears:- 4

Bevel Gears:- 5

Worm Gears:- 6

Rack and Pinion Gears:- 7

Advantages of gears:- 8

Disadvantages of gears 9

Application of gears:- 9

Gear manufacturing Selection of material:- 10

Mechanical Properties:- 10

Manufacturing properties:- 11

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Department of Mechanical Engineering

Environmental Properties:- 11

Economic Aspect:- 12

Gear manufacturing processes:- 13

Gear forming:- 13

Form milling:- 13

Broaching:- 13

Finishing operations:- 13

Calculations: 14

Normal System Helical Gear:- 14

Reference:- 16

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Objective:

The manufacturing techniques and operation are important aspect of manufacturing industry to

understand the effect of different parameters (i.e. process technique, material, speed, feed, material

removal rate or any other with respect to job) keeping in view flow / schematic diagrams, observations &

calculations and graphs as well as any other concepts involved in forming, shaping and metal joining

processes. Students can undertake the assigned job or select a job which involves 3-5 manufacturing

operations. For job manufacturing students are required to carry out the following tasks using

equipment/machines available in Machine Shop, CNC Shop, Project Lab or any other:

● Interpret and explain the concepts involved in forming, shaping and metal joining

processes with respect to job as well as the procedure for an Open Ended Lab.

● Perform manufacturing techniques / operations to prepare the desired jobs with precision.

● Formulate the CNC programing scheme of a component, generate codes, verify it using

CNC Machine or any CAD/CAM software and construct a job on CNC Machine

according to given design.

● Demonstrate positive individual work while performing Open Ended Lab as well as

follow the given instructions and deadlines.

● Summarize and report effectively various manufacturing

techniques/operations/components involved in OEL and their function in broad spectrum

of engineering and manufacturing processes/companies.

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Department of Mechanical Engineering

Theory:

Introduction:

A gear is a machine element used to transmit torque by power source having cut

teeth surface, mesh to another machine element (gear). Gears almost always

produce a change in torque, giving a mechanical advantage through their gear ratio

and can also be considered a simple machine. Among them one of the simple types

of the gear is Spur gear. It consists of a cylinder or disk with teeth. It transfer

torque from one shaft to the another shaft which is parallel to the driving shaft, axis

of rotation of two shafts are not coincide with each other. Spur gears are excellent

at moderate speeds but tend to be noisy at high speeds.

Different Types of Gears and Uses:-

Following are the different types of::

● Spur gears

● Helical gears

● Bevel gears

● Worm gears

● Rack and pinion

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Department of Mechanical Engineering

Spur Gears:-

The most common type of gears employed, spur gears are constructed with straight teeth cut or

inserted parallel to the gear’s shaft on a circular (i.e., cylindrical) gear body. In mated pairs, these

gears employ the parallel axes configuration to transmit motion and power. Depending on the

application, they can be mated with another spur gear, an internal gear (such as in a planetary

gear system), or a gear rack (such as in a rack and pinion gear pair).

The simplicity of the spur gear tooth design allows for both a high degree of precision and easier

manufacturability. Other characteristics of spur gears include lack of axial load (i.e., the thrust

force parallel to the gear shaft), high-speed and high-load handling, and high efficiency rates.

Some of the disadvantages of spur gears are the amount of stress experienced by the gear teeth

and noise produced during high-speed applications.

This type of gear is used for a wide range of speed ratios in a variety of mechanical applications,

such as clocks, pumps, watering systems, power plant machinery, material handling equipment,

and clothes washing and drying machines. If necessary for an application, multiple (i.e., more

than two) spur gears can be used in a gear train to provide higher gear reduction.

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Department of Mechanical Engineering

Helical Gears:-

Similar to spur gears, helical gears typically employ the parallel axes configuration with mated

gear pairs, but, if aligned properly, they can also be used to drive non-parallel, non-intersecting

shafts. However, unlike spur gears, these gears are constructed with teeth which twist around the

cylindrical gear body at an angle to the gear face. Helical gears are produced with right-hand and

left-hand angled teeth with each gear pair comprised of a right-hand and left-hand gear of the

same helix angle.

The angled design of helical teeth causes them to engage with other gears differently than the

straight teeth of spur gears. As properly matched helical gears come in contact with one another,

the level of contact between corresponding teeth increases gradually, rather than engaging the

entire tooth at once. This gradual engagement allows for less impact loading on the gear teeth

and smoother, quieter operation. Helical gears are also capable of greater load capabilities but

operate with less efficiency than spur gears. Further disadvantages include the complexity of the

helical tooth design, which increases the degree of difficulty in its manufacturing (and,

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consequently, the cost) and the fact that the single helical gear tooth design produces axial thrust,

which necessitates the employment of thrust bearings in any application which uses single

helical gears. This latter necessity further increases the total cost of using helical gears.

Bevel Gears:-

Bevel gears are cone-shaped gears with teeth placed along the conical surface. These gears are

used to transmit motion and power between intersecting shafts in applications which require

changes to the axis of rotation. Typically, bevel gears are employed for shaft configurations

placed at 90-degree angles, but configurations with lesser or greater angles are also manageable.

There are several types of bevel gears available differentiated mainly by their tooth design. Some

of the more common types of bevel gears include straight, spiral, and Zero bevel gears.

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Department of Mechanical Engineering

Worm Gears:-

Worm gear pairs are comprised of a worm wheel—typically a cylindrical gear—paired with a

worm—i.e., a screw-shaped gear. These gears are used to transmit motion and power between

non-parallel, non-intersecting shafts. They offer large gear ratios and capabilities for substantial

speed reduction while maintaining quiet and smooth operation.

One distinction of worm gear pairs is that the worm can turn the worm wheel, but, depending on

the angle of the worm, the worm wheel may not be able to turn the worm. This characteristic is

employed in equipment requiring self-locking mechanisms. Some of the disadvantages of worm

gears are the low transmission efficiency and the amount of friction generated between the worm

wheel and worm gear which necessitates continuous lubrication.

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University of Wah
Department of Mechanical Engineering

Rack and Pinion Gears:-

Rack and pinion gears are a pair of gears comprised of a gear rack and a cylindrical gear referred

to as the pinion. The gear rack can be considered as a gear of infinite radius (i.e., a flat bar) and

is constructed with straight teeth cut or inserted on the bar’s surface. Depending on the type of

pinion gear with which it is mated, the gear rack’s teeth are either parallel (when mated with spur

gears) or angled (when mated with helical gears). For either of these rack designs, rotational

motion can be converted into linear motion or linear motion can be converted into rotational

motion.

Some of the advantages of a rack and pinion gear pair are the simplicity of the design (and the

low cost of manufacturing) and high load carrying capacities. Despite the advantages of this

design, gears which employ this approach are also limited by it. For example, transmission

cannot continue infinitely in one direction as motion is limited by the designated length of the

gear rack. Additionally, rack and pinion gears tend to have a greater amount of backlash (i.e.,

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Department of Mechanical Engineering

additional space between mated gear teeth) and, consequently, the teeth experience a significant

amount of friction and stress.

Advantages of gears:-

1. By using gear trains, large velocity ratio can be obtained with minimum space.

2. Gears are mechanically strong, so higher loads can be lifted.

3. Gears are used for transmission of large H.F.

4. They are used for transmitting motion over small centre distance of shafts

5. They are used for large reduction in speed and for transmission of torque.

6. Gears require only lubrication, hence less maintenance is required.

7. Using gear systems, we can transmit motion between non-parallel intersecting shafts.

8. They are used for positive drive, so its velocity ratio remains constant.

9. They have long life, so the gear system is very compact.

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Department of Mechanical Engineering

Disadvantages of gears

1. They are not suitable for large velocities.

2. They are not suitable for transmitting motion over a large distance.

3. Due to the engagement of toothed wheel of gears, some part of machine may get

permanently damaged in case of excessive loading.

4. They have no flexibility.

5. Gear operation is noisy.

Application of gears:-

Gears are devices used throughout industry for a variety of mechanical machines and systems.

Several types of gears are available and employed in a wide range of residential, commercial,

and industrial applications, including:

● Aircrafts

● Automobiles

● Clocks

● Marine systems

● Material handling equipment

● Measuring instrumentation

● Power plants

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Department of Mechanical Engineering

● Pumps

Gear manufacturing Selection of material:-

Selecting a suitable material for both gears and shafts on which gears are mounted is very

important as material will specify the weight and maximum stresses that gear for shaft can take.

So for the proper working of the design it is very important to select the best material available

for the manufacturing of shafts and gears. To select the best material for the gear and shaft

following are the factors which must be consider during the selection process.

● Mechanical Properties

● Manufacturing Properties

● Environmental Properties

● Economic Factors

1.Mechanical Properties:-

Mechanical properties of the material used to manufacture a product will define the behavior of

the product under the action of any external force or stress during the mechanical operation.

Some of the specific mechanical properties that should be considered in this project are as follow

● Tensile strength

● Density

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● Ductility

● Wear resistance

Tensile strength of the material used will define the maximum force or the stresses that a product

made of that particular make can take. So it is very important that the selected material should

have good tensile strength. Density of the material will define the final weight of the product

made by that material. So it is very important that the selected material should have low density

so manufacture a light weight product. Ductility is the mechanical property which defines the

mode deformation of ay product under stress. A ductile material first under goes, elastic

deformation then plastic deformation and finally permanent failure whereas Brittle have no

deformation modes and it fails after the yield point. So it is very important that the selected

material should be ductile one. Wear resistance is one of the most important mechanical

properties required for this project as meshing gears wear with time due to friction between the

meshing teethes so material from which gears well me made should have excellent wear

resistance.

2. Manufacturing properties:-

Manufacturing properties of material are related to every product because to get any physical

product material has to pass through a certain manufacturing sequence. For ease in

manufacturing of this product material should have good machinability because gears and shafts

are made from machining process, gears specially form hobbling or milling and shafts from

turning process.

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Department of Mechanical Engineering

3. Environmental Properties:-

With the increase in awareness of the environmental problems cause by the waste material or

during the manufacturing of the product from the material, it is very important to select the

material which have lest effect of the environment. Properties which are associated with this tsk

are as follow

1. Embodied Energy

2. CO2 footprints

3. Recyclability

Embodied energy is the energy consume during the ores extraction, manufacturing and

decomposition of the material. Embodied is consider to be the most important property related to

the environmental aspects of the material at it covers all the energy of the associated with the

material. Material selected for manufacturing the product should have low embodied energy for

lower environmental effect. CO2 footprints are calculation of the amount of the CO2 associated

with the material during its complete lifecycle that is from extraction to decomposition. It is very

important with respect to the environmental aspects and the selected material should have lowest

CO2 footprint to have lowest effect on the environment. Recyclability is now considered to be

the most import property because it contributes in the environmental and economic aspects of the

product and material. So material selected for the manufacturing of the product should have good

recyclability.

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University of Wah
Department of Mechanical Engineering

4. Economic Aspect:-

Economic aspects are the final aspects which should be considered during the material selection.

In economic aspects material rate and material availability are the factor which influences the

material selection process. Selected material should be cheap and easily available to manufacture

product effectively.

Gear manufacturing processes:-

Gear forming:-

In gear form cutting, the cutting edge of the cutting tool has a shape identical with the shape of

the space between the gear teeth. Two machining operations, milling and broaching can be

employed to form cut gear teeth.

Form milling:-

In form milling, the cutter called a form cutter travels axially along the length of the gear tooth at

the appropriate depth to produce the gear tooth. After each tooth is cut, the cutter is withdrawn,

the gear blank is rotated, and the cutter proceeds to cut another tooth. The process continues until

all teeth are cut.

Broaching:-

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Department of Mechanical Engineering

Broaching can also be used to produce gear teeth and is particularly applicable to internal teeth.

The process is rapid and produces fine surface finish with high dimensional accuracy. However,

because broaches are expensive and a separate broach is required for each size of gear, this

method is suitable mainly for high-quality production.

Finishing operations:-

As produced by any of the process described, the surface finish and dimensional accuracy may

not be accurate enough for certain applications. Several finishing operations are available,

including the conventional process of shaving, and a number of abrasive operations, including

grinding, honing, and lapping.

 Normal System Helical Gear:-

In the normal system, the calculation of a profile shifted helical gear, the working pitch diameter

dw and transverse working pressure angle αwt is done per Equations (4.15). That is because

meshing of the helical gears in the transverse plane is just like spur gears and the calculation is

similar.

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University of Wah
Department of Mechanical Engineering

Table shows the calculation of profile shifted helical gears in the normal system. If normal

profile shift coefficientsxn1, xn2 are zero, they become standard gears.

N Symb Example
Item Formula
Pinion(1) Gear(2)
o. ol
1 Normal module mn 3
Normal pressure
2 αn 20 deg
angle
Reference cylinder
3 β 30 deg
helix angle Set Value
Number of teeth &
4 z 12 (L) 60 (R)
helical hand
Normal coefficient of
5 xn + 0.09809 0
profile shift
Transverse pressure
6 αt 22.79588 deg
angle
inv
7 Involute function αwt 0.023405
αwt
Transverse working
8 αwt Find from involute Function Table 23.1126 deg
pressure angle

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Department of Mechanical Engineering

Center distance

9 modification y 0.09744

coefficient

10 Center distance a 125.000

11 Reference diameter d 41.569 207.846

12 Base diameter db d cos αt 38.322 191.611

Working pitch
13 dw 41.667 208.333
diameter
ha1 ( 1 + y – xn2 ) mm
14 Addendum 3.292 2.998
ha2 ( 1 + y – xn1 ) mm
15 Tooth depth h {2.25 + y – ( Xn1 + Xn2 )}mm 6.748
16 Tip diameter da d + 2ha 48.153 213.842
17 Root diameter df da – 2h 34.657 200.346

Table: the calculations of a profile shifted helical gear in the normal system

Conclusion:-

In this lab, we learnt about the gears and their types. By the help of manufacturing knowledge we done

the calculation of Normal Helical Gear. Particular material initially selected for the job. Using different

machines to perform various operations at work. Finally we get the product.

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Department of Mechanical Engineering

Reference:-

1. https://en.wikipedia.org/wiki/Gear_manufacturing#:~:text=Gear%20manufacturing

%20refers%20to%20the,surface%20finish%20in%20the%20gear.

2. https://www.thomasnet.com/articles/machinery-tools-supplies/understanding-gears/

3. https://www.americanmachinist.com/machining-cutting/article/21900087/know-the-

differences-between-gear-finishing-processes

4. https://gearmotions.com/selection-of-gear-material/#:~:text=Gears%20can%20be

%20made%20of,of%20the%20material%20types%20mentioned.

5. https://khkgears.net/new/gear_knowledge/gear_technical_reference/calculation_gear_dim

ensions.html

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Department of Mechanical Engineering

Reference:-

6. https://en.wikipedia.org/wiki/Gear_manufacturing#:~:text=Gear

%20manufacturing%20refers%20to%20the,surface%20finish%20in%20the

%20gear.

7. https://www.thomasnet.com/articles/machinery-tools-

supplies/understanding-gears/

8. https://www.americanmachinist.com/machining-

cutting/article/21900087/know-the-differences-between-gear-finishing-

processes

9. https://gearmotions.com/selection-of-gear-material/#:~:text=Gears%20can

%20be%20made%20of,of%20the%20material%20types%20mentioned.

10.https://khkgears.net/new/gear_knowledge/gear_technical_reference/calculati

on_gear_dimensions.html
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Department of Mechanical Engineering

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