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Gear Manufacturing

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CEP
T

GEAR MANUFACTURING

INSTRUCTOR:
DR GHULAM HUSSAIN

GROUP MEMBERS REG NUMBER

AHMAD ABDUR REHMAN 2017036
MUHAMMAD DANIYAL 2017255
MUHAMMAD SAAIM SAJJAD 2017310
 TABLE OF CONTENTS

INTRODUCTION: _____________________________________________________________________ 3
A. Importance ___________________________________________________________________ 3
B. Purpose of the Project __________________________________________________________ 3
C. Methodology _________________________________________________________________ 4
ASSUMPTIONS: ______________________________________________________________________ 4
METHODOLOGY SELECTION: ___________________________________________________________ 5
Selection of Material: _______________________________________________________________ 5
Mechanical Properties: _____________________________________________________________ 5
Manufacturing Properties:___________________________________________________________ 6
Environmental Properties: ___________________________________________________________ 6
Economic Aspect: __________________________________________________________________ 6
MACHINING VS NON-TRADITIONAL MACHINING: __________________________________________ 7
METHODOLOGY:_____________________________________________________________________ 8
Gathering of Raw Material: __________________________________________________________ 8
Casting (Optional): _________________________________________________________________ 8
Sawing: __________________________________________________________________________ 9
Turning:__________________________________________________________________________ 9
Pocket Milling: ___________________________________________________________________ 10
Drilling: _________________________________________________________________________ 11
Hobbing: ________________________________________________________________________ 11
Gear Broaching: __________________________________________________________________ 12
FLOWCHART: ______________________________________________________________________ 13
COST AND ENERGY ANALYSIS: _________________________________________________________ 14
Cost of Raw Material:______________________________________________________________ 14
Sawing: _________________________________________________________________________ 14
Turning:_________________________________________________________________________ 15
1. Roughing: ___________________________________________________________________ 15
2. Finishing: ____________________________________________________________________ 15
Pocket Milling: ___________________________________________________________________ 16
Drilling__________________________________________________________________________ 17

1
 1. Drilling 8 small holes: __________________________________________________________ 17
2. Drilling 8 large holes: __________________________________________________________ 17
3. Drilling Central Hole: __________________________________________________________ 18
Hobbing ________________________________________________________________________ 18
Internal Broaching ________________________________________________________________ 19
CARBON ANALYSIS: _________________________________________________________________ 20
TOTAL ANALYSIS FOR 100 PARTS: ______________________________________________________ 20
CONCLUSION: ______________________________________________________________________ 20
REFERENCES:_______________________________________________________________________ 21

2
INTRODUCTION:
A gear is a rotating machine part having cut teeth, which mesh with another toothed part to transmit
torque. Geared devices can change the speed, torque, and direction of the power source. Gears almost
always produce a change in torque, giving a mechanical advantage through their gear ratio and can also
be considered a simple machine. There are several types of gears, among them the simplest type of gear
is the Spur gear. They consist of a cylinder or disk with teeth projecting radially. Although the teeth are
not straight sided, the edge of each tooth is straight and aligned parallel to the axis of rotation. These
gears mesh together correctly only if fitted to parallel shafts. No axial thrust is created by the tooth loads.
Spur gears are excellent at moderate speeds but tend to be noisy at high speeds.

A. Importance
Gears are very much important in our day to day life. Clocks, bicycles, automobiles and heavy-
duty industrial machines all rely on common gears and without these, we wouldn’t be able to live
the modern, convenient lives we live today. Spur gears are generally seen as best for applications
that require speed reduction and torque multiplication, such as ball mills and crushing equipment.
Examples of high-speed applications that use spur gears despite their high-level noise include,
consumer appliances such as washing machines and blenders. They are often used in aircraft
engines and trains.

B. Purpose of the Project

The purpose of this project was to design a spur gear as shown below in the figure 1.1 keeping in
mind the following aspects. Number of parts to be manufactured are 100, which means it is a
small batch. Carbon dioxide emission and energy consumption should be low. Parts that are
manufactured should have high accuracy and the cost should be low. There are several ways of
making a spur gear. All the processes were studied extensively, and a suitable process was
selected keeping in view the above aspects.

Figure 1.1

3
 C. Methodology
After researching extensively and consulting all the available processes from which a spur gear
can be manufactured, a suitable process was selected keeping in view the constraints provided
by the instructor. The first thing that comes to mind when deciding to manufacture something is
the material from which the object will be made. Similarly, for this project the material selected
was Mild Steel, due to its low cost and availability in the market. After this the next step would be
gathering of the material from suppliers. If the suppliers don’t have mild steel in cylindrical form,
then the gathered raw material can be turned into cylindrical form using casting process. After
that mild steel in form of cylindrical rods will be cut off into 100 parts of 15mm thickness. Initially
the rods would be of 66mm of outer diameter, using the turning process the outer diameter
length would be reduced to 60mm as shown in figure 1.2. After turning, the next step would be
to create a step in the cylinder. A 5mm step will be created on each face of the gear leaving an
inner thickness of 5mm. After that drilling process will be used to create holes. 8 holes of 6mm
diameter, 8 holes of 15mm diameter will be drilled in the area where pocket milling was done. 1
hole of 12mm diameter will be drilled in the center of the work piece. After that hobbing process
would be used to create external gear on the work pieces. The vertical length of each tooth i.e.
Addendum and Dedendum, would be 6mm. After hobbing, gear broaching process will be used
to create internal gear on the work pieces. The number of internal gears teeth will be 34 and their
vertical length would be of 3mm hence making the inner diameter a total of 15mm. After doing
cost, energy and environmental analysis the following results were achieved. (Anon., n.d.)

Total cost = Rs. 2410.8

Carbon emission = 5.09 kg
Energy Consumed = 13.6 kWh

ASSUMPTIONS:
Following were the assumptions that were made for the manufacturing of the gears:

Characteristics Dimensions
Initial Outer Diameter Before Turning 63 mm
Final Outer Diameter 60 mm
Inner Diameter 12 mm
Outer Base Diameter 54 mm
Inner Base Diameter 15 mm
Thickness 15 mm
Inner teeth 34
Outer teeth 54
Material Mild Steel
Gear Type Spur

4
 Figure 1.2

METHODOLOGY SELECTION:
Following are the aspects that were explored to the process used for manufacturing of the spur gear:

Selection of Material:
The first thing while manufacturing anything is selection of the material from which you will manufacture
the specified thing. Similar is the case with spur gear. The type of the material used depends on the
purpose for which the gear will be used. Some commonly used material for manufacturing of a spur gear
are Cast Iron, Stainless Steel and Acetal. The material selected for this project was mild steel.

Following characteristics should be kept in mind for the selection of a material for the spur gear:

➢ High tensile strength to prevent failures against static loads

➢ High endurance strength to withstand dynamic loads
➢ Low co-efficient of Friction
➢ Good manufacturability

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
➢ Ductility
➢ Wear resistance

5
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 lightweight
product. Ductility is the mechanical property which defines the mode deformation of ay product under
stress. A ductile material first undergoes, 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.

Manufacturing Properties:
Manufacturing properties of material are related to every product because to get any physical product
material must pass through a certain manufacturing sequence. For ease in manufacturing of this product
material should have good machinability because gears are made from machining process, gears
specially form hobbing.

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 has least
effect of the environment.

Properties which are associated with this task are as follows:

➢ Embodied Energy
➢ CO2 footprints
➢ Recyclability

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.

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.

6
MACHINING VS NON-TRADITIONAL MACHINING:
Contrary to traditional machining, non-traditional machining does not use a cutting tool to remove
material instead uses various forms of thermal, mechanical and chemical energy. Non-Traditional
machining involves high capital cost, complex equipment set-up and skilled labor. Tooling costs are
generally higher for non-traditional machining processes as compared to the traditional ones. Another
limitation of Non-Traditional machining process is that it is not suitable for every material economically.
Due to these reasons, Traditional Machining was preferred for this CEP. (Anon., n.d.)

7
METHODOLOGY:
Following is the methodology selected for the spur gear:

Gathering of Raw Material:

After the selection of the material, the next step is to gather the raw material from which the spur gear is
to be manufactured. Raw material can be gathered from different manufacturers or material suppliers.

Figure 3.1

Casting (Optional):
Casting is a manufacturing process in which a liquid material is usually poured into a mold, which
contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is known
as casting, which is ejected or broken out of the mold to complete the process. If the raw material is not
available in cylindrical form, raw material (cast iron) gathered will be casted in the form of a cylinder.

Figure 3.2

8
Sawing:
Sawing is a process wherein a narrow slit is cut into the work piece by a tool consisting of a series of
narrowly spaced teeth, called a saw blade. Sawing is used to cut off is used to separate work parts into
two or more pieces or to cut-off unwanted parts. Typically, the materials used for the making of saw are
High Speed Steel (HSS), Carbon Steel, High-speed Edge, and Tungsten Carbide tipped blades. Carbon Steel
was chosen as the material for the saw blades because of its general utility for a small lot and low cost.
The raw material brought from the suppliers will be cut in the specified number of parts i.e. 100 parts,
and sizes with the help of sawing machine. The thickness of the stock after sawing would be 15mm.

Figure 3.3

Turning:
Turning is a cutting operation in which a single point cutting tool removes material from a rotating
workpiece to generate a cylinder. Turning operation is performed on a machine tool called Lathe.
Various types of turning operations can be performed such as Facing, Contour turning, Chamfering, and
Threading. Conventional turning will be applied to the parts, in which the tool is fed longitudinally at a
certain depth of cut to reduce the diameter of the stock. The outer diameter of the stock after turning
would be 60mm.

9
 Figure 3.4

Pocket Milling:
Milling is a machining operation in which the workpiece is fed past a rotating tool with multiple cutting
edges. Cutting tool is called a milling cutter. Typically, two types of milling operations exist i.e. Face and
Peripheral Milling. In face milling, the cutter axis is perpendicular to the surface being milled whereas in
peripheral milling the cutter axis is parallel to the surface. Pocket milling is a type of end milling, which is
used to create shallow pockets in flat surfaces. Pocket milling will be used to create shallow circular
pockets of 5mm on each face of the stock leaving a thickness of 5mm. [4]

Figure 3.5

10
Drilling:
Drilling is an operation used to create round holes in work pieces. Cutting tool for drilling operation is
called a drill bit and machining tool is called a drill press. Drill bit comes in various sizes in order to create
holes of different sizes. Two types of drilling holes exist i.e. Through holes and Blind holes. Through
holes are the ones in which drill exists opposite side of the work piece whereas blind holes are the ones
in which the drill doesn’t exit the opposite side of the work piece. In this project, after pocket milling
drilling operation will be used to cut 8 holes of 6mm, 8 holes of 15mm and 1 hole of 12mm in the center
as shown in figure 1.2. All holes will be through holes.

Figure 3.6

Hobbing:
Hobbing is a machining process for gear cutting, cutting splines, and cutting sprockets on a hobbing
machine. It is a special type of milling machine. The teeth or splines of the gear are progressively cut into
the material by a series of cuts made by a cutting tool called a hob. It is the most widely used gear
cutting process for creating spur and helical gears. If a spur gear is being produced, then the hob is
angled equal to the helix angle of the hob, if a helical gear is being produced then the angle must be
increased by the same amount as the helix angle of the helical gear. Compared to other gear forming
processes, hobbing is quick, inexpensive and quite accurate, thus it is used for a broad range of parts
and quantities. After drilling, hobbing operation will be applied to the stock to generate spur gears with
a vertical length of 6mm. [7]

11
 Figure 3.7

Gear Broaching:
Broaching is a machining process that uses a toothed tool, called broach. There are two types of
broaching: linear and rotary. Broaching can be used to generate external as well as internal gears. In this
project we will use gear broaching process to generate internal gear with 34 teeth in the work pieces
after the hobbing process. [6]

Figure 3.8

12
FLOWCHART:

Sawing for cutting

Selection of Gathering Raw
workpiece to given
Material Material
thickness

Pocket Milling for

Drilling for creating Turning for
creating step in
holes diameter reduction
workpieces

Hobbing for Broaching for

generating generating internal
external gear gear

13
COST AND ENERGY ANALYSIS:

Cost of Raw Material:

Volume of starting workpiece: π × (𝐷0 /2)2 × 𝑇

Volume of starting workpiece = π × (63 × 10−3 /2)2 × 15 × 10−3 = 4.68 × 10−5 𝑚3

Density of Mild Steel: 7850 kg/m3

Number of Parts required: 100

Mass of 100 parts: Density × Volume × No. of Parts

Mass of 100 parts = 7850 × 4.68 × 10−5 × 100 = 36.738 𝐾𝑔

Cost of Mild Steel per Kg = Rs 60

Total Cost of Raw Material Required = Cost/ Kg × Mass of 100 parts = 60 × 36.738 = 𝑅𝑠 2204.3

Sawing:
f = 1 (mm/rev)

v = 30480 (mm/min)

𝑁 = 154 𝑟𝑒𝑣⁄𝑚𝑖𝑛
Now,

So, 𝐹𝑟 = 154 𝑟𝑒𝑣⁄𝑚𝑖𝑛 × 1 𝑚𝑚⁄𝑟𝑒𝑣

𝐹𝑟 = 154 𝑚𝑚⁄𝑚𝑖𝑛
Now,

63𝑚𝑚
𝑇𝑚 = = 0.40 𝑚𝑖𝑛
154 𝑚𝑚⁄𝑚𝑖𝑛
For 100 parts,

𝑇 = 40𝑚𝑖𝑛

14
 40
𝐸 =3× = 2 𝑘𝑤ℎ
60
𝐶𝑜𝑠𝑡 = 2 × 15 = 𝑅𝑠. 30
Therefore, sawing electricity cost = Rs.30

Turning:
1. Roughing:

Known Quantities:
𝑓𝑟𝑜𝑢𝑔ℎ = 1.25 𝑚𝑚⁄𝑟𝑒𝑣
𝑉𝑟𝑜𝑢𝑔ℎ = 0.51 𝑚⁄𝑠
𝐷𝑂,𝐼 = 63 𝑚𝑚
𝑇 = 15 𝑚𝑚
𝑑 = 2 𝑚𝑚

0.51
𝑁= = 2.57 𝑟𝑒𝑣⁄𝑠
π × 63 × 10−3

𝑓𝑟,𝑅 = 2.57 × 1.25 × 10−3 = 3.21 × 10−3 𝑚/𝑠

𝑇𝑚,𝑅 = 15 × 10−3⁄3.21 × 10−3 = 4.67 𝑠

2. Finishing:

Known Quantities:
𝑓𝑓𝑖𝑛𝑖𝑠ℎ = 0.750 𝑚𝑚/𝑟𝑒𝑣
𝑉𝑓𝑖𝑛𝑖𝑠ℎ = 0.7 𝑚/𝑠
𝐷𝑂,𝐹 = 60 𝑚𝑚
𝑇 = 15 𝑚𝑚
𝑑 = 1 𝑚𝑚

𝑁 = 0.70⁄ π × 60 × 10−3 = 3.71 𝑟𝑒𝑣/𝑠

𝑓𝑟,𝐹 = 3.71 × 0.750 × 10−3 = 2.78 × 10−3 𝑚/𝑠

15
 𝑇𝑚,𝐹 = 15 × 10−3⁄2.78 × 10−3 = 5.40 𝑠

Total Time for turning:

𝑇𝑇,𝑇 = 4.67 + 5.40 𝑠 = 10.07𝑠

For 100 parts,

𝑇 = 10.07 × 100
𝑇 = 1007 𝑠

Power Rating of a Single Column Vertical Lathe= 8 KW

𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑖𝑡𝑦 𝐶𝑜𝑠𝑡 𝑓𝑜𝑟 100 𝑝𝑎𝑟𝑡𝑠 = 2.24 x 15= Rs. 33.6

Pocket Milling:
Depth of cut (d) = 2.5mm

w = 5mm

N = 1000 rpm

f = 0.5 mm/rev

𝑓𝑟 = 1000 × 0.5 × 4 = 2000 𝑚𝑚/𝑚𝑖𝑛

𝑅𝑀𝑅 = 25000 𝑚𝑚3 /𝑚𝑖𝑛

Volume removed (excluding the central area) = 4250 mm3

Time = 4250/25000 = 10.4 s

Time for both sides = 20.8 s

Time for 100 parts = 2080 s

Power Rating of a CNC Milling Machine= 7.5 KW

2080
𝐸𝑚𝑖𝑙𝑙𝑖𝑛𝑔 = × 7.5 = 4.33𝐾𝑊ℎ
3600
𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑖𝑡𝑦 𝐶𝑜𝑠𝑡 𝑓𝑜𝑟 100 𝑝𝑎𝑟𝑡𝑠 = 15 × 4.33 𝐾𝑊ℎ = 𝑅𝑠 64.95

16
Drilling
1. Drilling 8 small holes:

Known Quantities:

𝑓𝑑𝑟𝑖𝑙𝑙 = 0.50 mm/rev

𝑉𝑑𝑟𝑖𝑙𝑙 = 0.75m/s
𝐷𝑑𝑟𝑖𝑙𝑙,𝑠 = 6 mm
𝑇𝑛𝑒𝑤 = 5 mm
Ѳ = 118ᵒ

𝑁 = 0.75 ⁄ π × 6 × 10−3 = 39.79 𝑟𝑒𝑣/𝑠

𝑓𝑟,𝑑𝑟𝑖𝑙𝑙 = 39.79 × 0.50 × 10−3 = 20 𝑚𝑚/𝑠

118
𝐴 = 0.5 × 6 × 10−3 × tan (90 − ) = 1.8025 𝑚𝑚
2

(5 × 10−3 + 1.8025 × 10−3 )⁄

𝑇𝑇,𝐷𝑆 = 0.02 = 0.34 𝑠
2. Drilling 8 large holes:

Known Quantities:

𝑓𝑑𝑟𝑖𝑙𝑙 = 0.50 mm/rev

𝑉𝑑𝑟𝑖𝑙𝑙 = 0.75m/s
𝐷𝑑𝑟𝑖𝑙𝑙,𝑠 = 15 mm
𝑇𝑛𝑒𝑤 = 5 mm
Ѳ = 118ᵒ

𝑓𝑟,𝑑𝑟𝑖𝑙𝑙 = 15.92 × 0.50 = 7.96 𝑚𝑚/𝑠

(5 + 4.51)⁄
𝑇𝑇,𝐷𝐿 = 7.96 = 1.19 𝑠

17
 3. Drilling Central Hole:

Known Quantities:

𝑓𝑑𝑟𝑖𝑙𝑙 = 0.50 mm/rev

𝑉𝑑𝑟𝑖𝑙𝑙 = 0.75m/s
𝐷𝑑𝑟𝑖𝑙𝑙,𝑠 = 12 mm
𝑇= 15 mm
Ѳ = 118ᵒ

𝑓𝑟,𝑑𝑟𝑖𝑙𝑙 = 19.89 × 0.50 × 10−3 = 9.95 𝑚𝑚/𝑠

118
𝐴 = 0.5 × 12 × tan (90 − ) = 3.61𝑚𝑚
2

(15 + 3.61)⁄
𝑇𝑇,𝐷𝐶 = 9.95 = 1.87 𝑠
𝑻𝒐𝒕𝒂𝒍 𝑻𝒊𝒎𝒆 𝒕𝒐 𝑫𝒓𝒊𝒍𝒍 (𝑇𝑇,𝐷 ) = 0.34 𝑠 + 1.19 𝑠 + 1.87 𝑠

𝑇𝑇,𝐷 = 3.4 𝑠

Time for 100 parts = 340 s

Power Rating of a Multi Spindle Drilling Machine= 3.7 kW

340
𝐸𝑑𝑟𝑖𝑙𝑙𝑖𝑛𝑔 = × 3.7 = 0.35 𝑘𝑊ℎ
3600
𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑖𝑡𝑦 𝐶𝑜𝑠𝑡 𝑓𝑜𝑟 100 𝑝𝑎𝑟𝑡𝑠 = 15 × 0.35 𝑘𝑊ℎ = 𝑅𝑠 5.24

Hobbing
𝑚𝑚 𝑚
Known Quantities: 𝐾 = 1, 𝑍 = 54, 𝑓ℎ𝑜𝑏 = 6 ,𝑤 = 0.5 𝑚𝑚, 𝐷ℎ𝑜𝑏 = 24𝑚𝑚, 𝑉ℎ𝑜𝑏 = 1.3
𝑟𝑒𝑣 𝑠

𝐿ℎ𝑜𝑏 = 15 + 11.75 = 31.75 𝑚𝑚

𝑁 = 1.3⁄ π × 24 × 10−3 = 17.24 𝑟𝑒𝑣/𝑠

18
 54 × 31.75
𝑇𝑇,𝐻 = = 16.57 𝑠
17.24 × 1 × 6
Time for 100 parts= 1657 s

Power rating of Hobbing Machine= 8 kW

1657
𝐸ℎ𝑜𝑏𝑏𝑖𝑛𝑔 = × 8 = 3.70 𝐾𝑊ℎ
3600
𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑖𝑡𝑦 𝐶𝑜𝑠𝑡 𝑓𝑜𝑟 100 𝑝𝑎𝑟𝑡𝑠 = 15 × 3.70𝐾𝑊ℎ = 𝑅𝑠. 55.5

Internal Broaching
Known Quantities: 𝐿𝑏 = 500𝑚𝑚, 𝑇 = 𝐿𝑤 = 15𝑚𝑚, 𝑉𝑏 = 0.05 𝑚/𝑠

((500 + 15) × 10−3 )⁄

𝑇𝑇,𝐼𝐵 = 0.05 = 10.3 𝑠
Time for 100 parts= 1030 s

Power Rating of an Internal Broaching Machine= 4 KW

1030
𝐸𝑏𝑟𝑜𝑎𝑐ℎ𝑖𝑛𝑔 = × 4 = 1.14 𝐾𝑊ℎ
3600
𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑖𝑡𝑦 𝐶𝑜𝑠𝑡 𝑓𝑜𝑟 100 𝑝𝑎𝑟𝑡𝑠 = 15 × 1.14 𝑘𝑊ℎ = 𝑅𝑠 17.20

19
CARBON ANALYSIS:
0.947 (kWh) produce 0.351 kg of CO2

PROCESS ENERGY CONSUMED MASS(kg)

(kWh) Calculation Answer
Sawing 2.00 0.351 × 2.00 0.74
0.947
Turning 2.24 0.351 × 2.24 0.83
0.947
Pocket milling 4.33 0.351 × 4.33 1.60
0.947
Drilling 0.35 0.351 × 0.35 0.13
0.947
Hobbing 3.70 0.351 × 3.70 1.37
0.947
Internal broaching 1.14 0.351 × 1.14 0.42
0.947
TOTAL CO2 EMISSION - - 5.09

TOTAL ANALYSIS FOR 100 PARTS:

PROCESS FUNCTION POWER CO2 EMISSIONS TIME TAKEN PRICE
CONSUMPTION (KG) (SEC) (PKR)
(KWH)
Sawing Cut blank 2.00 0.74 2400 30
Turning Dia reduction 2.24 0.83 1007 33.6
Pocket milling Create pocket 4.33 1.60 2080 64.95
Drilling Making holes 0.35 0.13 340 5.24
Hobbing External teeth 3.70 1.37 1657 55.5
Internal Broaching Internal teeth 1.14 0.42 1030 17.20
TOTAL 13.76 5.09 8514 206.5

Total cost= Rs. 206.5 + material cost (2204.3)

Therefore, the total cost of gear is PKR 2410.8.

CONCLUSION:
After comparing different ways of producing a spur gear above mentioned process was selected as the
best suitable process keeping in mind the following restrictions i.e. number of parts, accuracy, carbon
emission and cost. By following this method one can generate a spur gear with minimum cost. After
doing cost, energy and environmental analysis the following results were achieved.
Total cost= Rs. 2410.8
Carbon emission = 5.09kg
Energy Consumed = 13.6 KWh.

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 REFERENCES:

1. https://rwdtool.com/conventional-machining-vs-non-conventional-machining-
process/blog.html
2. http://www.difference.minaprem.com/ntm/difference-between-conventional-machining-and-
non-traditional-machining-ntm/
3. https://en.wikipedia.org/wiki/Milling_(machining)
4. https://bobcad.com/cnc-software-what-is-pocket-milling/
5. https://www.millerbroach.com/what-is-broaching/
6. https://en.wikipedia.org/wiki/Broaching_(metalworking)
7. https://en.wikipedia.org/wiki/Hobbing
8. https://www.quora.com/What-are-important-properties-of-material-for-gear-application
9. https://www.ctemag.com/news/articles/fundamentals-industrial-sawing
10. https://www.machinesells.com/new-machine/new-machine-for-sell-871498699
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159.html
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Press-ZQJ525W-.html
13. https://www.machineseeker.com/wgw-nzh+90%2F430/i-4308098

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