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Gear Manufacturing Processes Analysis

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 Gear Manufacturing Process Analysis
M. Ibrahim Khan
Faculty of Mechanical Engineering
Ghulam Ishaq Khan Institute
Swabi, Pakistan

Abstract—The purpose of this project is to provide an B. Machines Used for Analysis

economical, environment friendly and time efficient process for
In Table 2; the machines considered for analysis any their
manufacturing a batch of 100 gears. the main objective is to list
down all the possible processes of manufacturing and selecting specific types are stated to provide a much accurate
the most suitable chain of processes. analysis. The machines used in the analysis are most used
in the industries nowadays, which increases the impact of
Keywords—Gear, Grinding, Hobbing, Shaping, Skiving, solution.
Chamfer, Deburring, Press, Casting
Machine Idle Cutting Power
I. INTRODUCTION Process Model Type kWh kWh Specification Supply
Gears are one of the most important way of power LGG 400 GH
transmission used in industries such as automobile and Grinding M[3] 4.0 6.78 35 10000 rpm Electric
robotics etc. There have been several conventional ways to LC Driect
make gears and they are increasing with time, and even the Hobbing 400[4] Head 5.56 26 4500 rpm Electric
LS 400
design of the gear has improved with time. Nowadays there
Shaping EM[5] 5.27 19.5 1500 ds/min Electric
are there are specialized gears types and sizes for each use LK
which has been optimized for a that task using multiple Skiving 400[6] 4.58 32 2700 rpm Electric
analytical analysis[1]. To achieve those attributes of the gears Profile LGF
there are chains of processes amongst which they are selected Grinding 800[3] 15.23 23 3730 rpm Electric
by the processes of give and take. Chamfer LD 300
Deburring C[7] 5.49 25 1500 rpm Electric
II. LITERATURE REVIEW FUKUI 20
Press 1200 37 132 sec/stroke Electric
A. Gear Manufacturing Processes SD 850
There are several gear manufacturing processes, but in this Casting CH 5.88 45 7 m/sec Electric
research paper we will consider the most conventional Central Furn-
methods. The manufacturing processes that will be considered Heating Teck 770 250 kg/hr Petrol
are: Turning, Grinding, Hobbing, Shaping, Milling, Skiving, Liquid MS Furn-
Die Casting and Sand Casting[2]. These are most of the Holder Teck 225 3000 kg Petrol
processes currently being used by industries to make gears.
Table 2: Machines Considered for Analysis with Required
B. Gear Finishing Processes Specifications
The gears produced are not according to dimensions or
needs slight surface finish. So, in this paper we will consider C. Time and Energy Analysis
the process of Profile Grinding, Chamfering and
Deburring[2].
III. METHODOLGY FOR CALCULATION
The Calculations were done by taking some assumptions
given bellow in Table 1. Firstly, MRR was calculated for each
machine and finding time of machining. Gaps were added
between each unit in which the machine was considered idle.
Both times were multiplied with the given data of specified
machines. This gave us the time consumed for each process
and energy requirement.
This data was further used to calculate the economic factor
and the impact on the environment. For this, standard charges
of electricity and fuel were used that were available at the time
of research.
Table 3: Options for Gear Manufacturing Processes and Energy
A. Assumtions Analysis
Outer Diameter 300
Outer Base Diameter 290 The above table was generated using available tabular
Weidth 10 data and the datasheets of the above specified machines.
Inner Diameter 100
Inner Base Diameter 90
D. CO2 Emission Analysis
Inside Teeth 100 CO2 Emission Energy in one liter of fuel
Outer Teeth 200 Electricity 0.283 kg/kW Fuel 9 kW/liter
Metal Mild Steel Fuel 2.4 kg/liter
Table 1: Assumptions Table 4: Assumptions for CO2 Emission Analysis[8]

Gear Manufacturing Processes Analysis

 A. Analysis on The Choosen Chain of Processes

Table 8: Analysis of The Optimized Solution

The above analysis give the solution that by using the

optimized chain, identified previously, we will generate:
around 343 kg of CO2, cost 16350 Rupees excluding common
Table 5:Options for Gear Manufacturing Processes and CO2 charges, and will take around 3.4 hours with power
Emission Analysis requirement of 1213 kW.

E. Cost Analysis ACKNOWLEDGMENT

I would like to thank the All-Mighty Allah, and my family
Eletricity Price 13.48 per kW to make me stand in this position. I would also like to thank
Fuel Price 81.58 per liter Faculty of Mechanical Engineering Ghulam Ishaq Khan for
Table 6: Prices of Types of Power Supplies[9, 10] providing me with the required information, and I would like
to specially thank Dr. Ghulam Hussain for solving all my
queries and helping me in my research.
REFERENCES
1. Al-Ghamdi, K. and G. Hussain, On the CO 2
characterization in incremental forming of roll
bonded laminates. Journal of Cleaner Production,
2017. 156.
2. Carroll, C. Gear Manufacturing Processes.
Available from:
https://slideplayer.com/slide/12682178/.
3. LIEBHERR, Generating- and profile-grinding
machines LGG 180 / 280.
Table 7:Options for Gear Manufacturing Processes and Cost 4. LIEBHERR, Hobbing machines
Analysis LC 200–500.
5. LIEBHERR, LS 400 EM Gear Shaping Machine
The above calculations were made by adding the prices of with electronic helical guide.
power supply, labor cost etc. Common costs such as fixed 6. LIEBHERR, Gear Skiving Machines
charges, taxes etc. are excluded from the analysis. LK 300 / 500.
IV. RESULTS 7. LIEBHERR, Chamfering and Deburring Machine
LD 300 C.
Optimized solution depends upon the choices you make. It 8. Ecosore. CO2 emission from the fuel consumption.
depends upon what is degree of importance of each aspect of Available from:
the processes. Nowadays, the world is going towards green
https://ecoscore.be/en/info/ecoscore/co2.
processes so we will give the most importance to quality and
9. Urdupoint. Petrol Prices in Pakistan. Available
then CO2 Emission. After that the most important thing is the
economics and the time taken. from:
https://www.urdupoint.com/business/petroleum-
For the Center hole we will choose the process of milling prices-in-pakistan.html.
as it is cheaper, faster, and lesser CO2 Emission. Next, we will 10. iesco. SCHEDULE OF ELECTRICITY TARIFFS.
choose Hobbing for outer teeth followed by Skiving for inner Available from:
teeth. For the finishing processes we will choose both https://iesco.com.pk/index.php/customer-
Grinding and Chamfering as they both are important services/tariff-guide.

Gear Manufacturing Processes Analysis

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