DESIGN, FABRICATION AND ANALYSIS OF Al-TiB2 GEAR

ABSTRACT
Gears play a pivotal role in mechanical power transmission systems and rotating machinery.
Typically, gear tooth failure occurs when the load surpasses a certain threshold. Hence,
diverse materials are essential for gear manufacturing. Metal matrix composites offer
enhanced properties, including heightened strength, increased stiffness, and reduced weight
compared to unreinforced alloys. This study aims to replace metallic gears with composite
gears made of aluminium titanium diboride to enhance machine performance and prolong
working life. Aluminium alloy and TiB2 serve as the matrix and reinforcing material,
respectively. Contact stress, a crucial parameter in gear design, is analysed in Al-TiB2 gear
pairs using Hertz theory and finite element analysis (FEA) via ANSYS.

The study utilizes aluminium titanium diboride as a gear material, and experimental stresses
are determined using the strain gauge technique. Comparison reveals a notable alignment
between theoretical and FEA results with experimental findings. The use of composite
material results in an approximately 18% reduction in stresses, and the composite's weight is
nearly three times less than steel. Consequently, composites present a viable option for
manufacturing power-transmitting components like gears subjected to continuous loading.

Aluminium Titanium Diboride (Al-TiB2) as a composite material for gears is driven by its
unique combination of properties. Al-TiB2 is known for its exceptional hardness, wear
resistance, and thermal stability, making it a suitable candidate for applications requiring
robust and durable components. The use of this composite material in gears not only
addresses the challenges of load-induced failures but also contributes to increased reliability
and efficiency in mechanical systems.

1
DESIGN, FABRICATION AND ANALYSIS OF Al-TiB2 GEAR

CHAPTER- 1
INTRODUCTION
The project titled "Design, Fabrication, and Analysis of Aluminium Titanium Diboride (Al-
TiB2) Gear" represents an innovative exploration into advanced materials for gear
manufacturing. Gears are crucial components in mechanical power transmission systems and
rotating machinery, prompting the search for materials that can enhance their performance.
This project specifically focuses on leveraging Aluminium Titanium Diboride, a unique
composite material, to design, fabricate, and analyse gears with the goal of enhancing their
strength, wear resistance, and overall efficiency.

Traditional metallic gears encounter challenges, particularly under high loads, leading to
wear and failure. This project addresses these challenges by investigating metal matrix
composites, particularly Al-TiB2, known for their exceptional properties such as high
strength, wear resistance, and reduced weight compared to traditional alloys. Integrating these
advanced materials in gear design has the potential to significantly improve gear performance
and longevity across various mechanical systems.

The design phase of the project involves a meticulous process to optimize gear geometry
while considering the unique properties of Al-TiB2. Finite Element Analysis (FEA) is
utilized to simulate and validate the design, ensuring structural integrity and the ability to
withstand diverse operational conditions. The objective is to leverage the superior
characteristics of Al-TiB2 to enhance gear performance in terms of load-bearing capacity and
wear resistance.

In the fabrication phase, advanced manufacturing techniques like powder metallurgy or

sintering are employed to produce gears from Al-TiB2 composite material. The focus is on
achieving a uniform distribution of TiB2 particles within the aluminium matrix to ensure
consistent mechanical properties and structural integrity. Precise control of the fabrication
process is crucial to fully harness the potential of Al-TiB2 in enhancing gear strength and
durability.

The final phase involves a comprehensive analysis of the fabricated Al-TiB2 gears,
systematically evaluating mechanical properties including tensile strength, hardness, and
wear resistance. Theoretical methods and finite element analysis (FEA) using tools like
ANSYS are used to simulate gear behaviour under various operating conditions.
Additionally, experimental testing, including contact stress analysis using Hertz theory, offers
practical insights into the real-world performance of the gears.

This project has significant potential to advance gear technology by introducing a novel
material solution. Successful implementation of Al-TiB2 composite gears could lead to
improved efficiency, longevity, and reduced weight in mechanical systems, impacting
industries from aerospace to automotive and machinery. The combination of innovative
design, advanced fabrication techniques, and comprehensive analysis positions this research
at the forefront of material science and mechanical engineering.

2
DESIGN, FABRICATION AND ANALYSIS OF Al-TiB2 GEAR

CHAPTER- 2
LITERATURE REVIEW

1. Pawar and Utpat have developed a metal matrix composite of aluminium based
silicon carbide. Authors has done FEA of gear using ANSYS 14.0 and concluded that
composite gears offer improved properties over steel alloys and can be replaced with
metallic gears.

2. Saravanan and Kumar have developed metal matrix composites by varying rice
husk ash percentage and concludes that with increase in percentage of rice husk ash in
metal matrix composites will increase ultimate tensile strength, compressive strength,
and hardness of the composite.

3. Devi et al. conducted experiments for tensile strength by varying mass fraction of Sic
with aluminium and found that aluminium silicon carbide composite material is
having less weight and more strength.

4. Suragimath and Purohit conducted experiment by varying fly ash weight fraction
with constant SiC and found that the increase in addition of fly ash increases the
tensile strength, impact strength, wear resistance of the specimen and decreases the
percentage of elongation.

5. Hassan considered different contact positions for contact stress analysis between two
spur gear teeth, representing a pair of mating gears during rotation and developed a
programme to plot a pair of teeth in contact.

6. Hwang et al. presents a contact stress analysis for a pair of mating gears during
rotation and performed contact stress analysis for spur and helical gears between two
gear teeth at different contact positions during rotation.

7. Tiwari and Joshi presented analysis of bending stress and contact stress of involute
spur gear teeth and found that hertz theory is the basis of contact stress calculation.
Theoretical results which are obtained from Lewi’s formula and Hertz equation are
comparable with FEA results.

8. Khan and Mangla analyzed contact stress of spur gears by theoretical method using
Hertz equations and by FEA using ANSYS 14.0 workbench. The spur gear is
sketched, modelled, and analysed using ANSYS. It is found that the results obtained
from theoretical method and FEA are comparable with each other.

3
DESIGN, FABRICATION AND ANALYSIS OF Al-TiB2 GEAR

CHAPTER- 4
OBJECTIVES

 Material Innovation:
Investigate the unique properties of Aluminium Titanium Diboride (Al-TiB2) composite
material.

 Gear Design Optimization:

Conduct a meticulous design phase to optimize gear geometry, considering the distinctive
properties of Al-TiB2.

 Fabrication Techniques:
Employ advanced manufacturing techniques, such as powder metallurgy or sintering, to
fabricate gears using the Al-TiB2 composite material.

 Performance Analysis:
Systematically evaluate the mechanical properties of the fabricated Al-TiB2 gears,
including tensile strength, hardness, and wear resistance.

 Real-world Validation:
Conduct experimental testing, including contact stress analysis using Hertz theory, to
provide practical insights into the real-world performance of Al-TiB2 gears.

 Potential Impact on Industries:

Assess the project's significance in contributing to the advancement of gear technology by
introducing Al-TiB2 composite gears.

 Dissemination of Findings:
Communicate and disseminate the research findings through publications, presentations,
and reports to contribute to the broader scientific and engineering community.

4
DESIGN, FABRICATION AND ANALYSIS OF Al-TiB2 GEAR

CHAPTER- 5
METHODOLGY

DESIGN PHASE

MATERIAL SELECTION

FABRICATION PROCESS

ANALYSIS AND
PEFORMANCE EVALUATION

DOCMENTATION AND
REPORTING

5
DESIGN, FABRICATION AND ANALYSIS OF Al-TiB2 GEAR

CHAPTER- 6
FUTURE SCOPE

The project "Design, Fabrication, and Analysis of Aluminium Titanium Diboride (Al-
TiB2) Gear" sounds intriguing and futuristic. Here's a breakdown of potential future
scopes for this project:

1. Material Optimization: Further research can focus on optimizing the composition

of the Al-TiB2 alloy for enhanced mechanical properties, such as strength, hardness,
and wear resistance. This could involve experimenting with different ratios of
aluminium, titanium, and diboride to achieve the desired properties.

2. Advanced Fabrication Techniques: Explore advanced fabrication techniques

such as additive manufacturing (3D printing) or advanced casting methods to produce
gears with complex geometries and improved mechanical properties. These
techniques can offer higher precision, customization, and potentially lower costs
compared to traditional manufacturing methods.

3. Performance Testing and Analysis: Conduct comprehensive performance testing

and analysis of the Al-TiB2 gears under various operating conditions, including
different loads, speeds, temperatures, and environments. This would help validate
their mechanical properties, durability, and suitability for specific applications.

4. Applications in Aerospace and Automotive Industries: Investigate the

feasibility of using Al-TiB2 gears in aerospace and automotive applications where
lightweight, high-strength materials are crucial for improving fuel efficiency,
performance, and reliability. Collaborate with industry partners to explore potential
applications and market demand.

5. Integration with Emerging Technologies: Explore opportunities to integrate Al-

TiB2 gears with emerging technologies such as electric vehicles, drones, and robotics.
These applications could benefit from the lightweight and high-strength properties of
the material, enabling more efficient and reliable mechanical systems.

6
DESIGN, FABRICATION AND ANALYSIS OF Al-TiB2 GEAR

6. Environmental Sustainability: Consider the environmental impact of the

manufacturing process and the lifecycle of Al-TiB2 gears. Explore ways to optimize
production processes to reduce energy consumption, waste generation, and carbon
footprint, aligning with sustainability goals and regulations.

7. Cost Optimization: Investigate methods to optimize the cost-effectiveness of

producing Al-TiB2 gears without compromising quality and performance. This could
involve improving manufacturing efficiency, sourcing cost-effective raw materials,
and streamlining supply chains.

8. Collaborative Research: Foster collaboration with research institutions, industry

partners, and government agencies to leverage expertise, resources, and funding
opportunities for advancing the development and commercialization of Al-TiB2 gears.
This could involve participating in joint research projects, sharing knowledge and
data, and pursuing grant funding.

By exploring these future scopes, the project can contribute to advancing the field of
materials science and engineering, as well as addressing practical challenges in
various industries.

7
DESIGN, FABRICATION AND ANALYSIS OF Al-TiB2 GEAR

CHAPTER- 7
CONCLUSION
The project "Design, Fabrication, and Analysis of Aluminium Titanium Diboride Gear" holds
promising future prospects in several areas:

Material Advancements: Aluminium titanium diboride (Al-TiB2) is an emerging material

known for its high strength, wear resistance, and thermal stability. Further research and
development in this field could lead to advancements in various industrial applications
beyond just gears, including aerospace, automotive, and machinery manufacturing.

Performance Optimization: Through thorough analysis and testing, the project can lead to the
optimization of gear design and fabrication processes, resulting in gears with enhanced
performance characteristics such as improved durability, reduced friction, and increased
efficiency.

Industry Applications: Gears are fundamental components in many mechanical systems. The
successful implementation of Al-TiB2 gears can have a significant impact on industries
relying on high-performance gears, such as aerospace, automotive, robotics, and heavy
machinery. It could lead to more efficient and reliable systems in these sectors.

Cost-Effectiveness: While initial fabrication costs may be higher due to the use of advanced
materials and processes, the long-term benefits such as increased lifespan and reduced
maintenance could outweigh the initial investment, making Al-TiB2 gears a cost-effective
solution in the long run.

Environmental Impact: Enhanced durability and efficiency of Al-TiB2 gears can contribute to
sustainability efforts by reducing the need for frequent replacements and maintenance, thus
lowering overall resource consumption and environmental impact associated with gear
manufacturing and disposal.

Further Research Opportunities: The project opens doors for further research avenues, such
as exploring the properties of Al-TiB2 composites under different operating conditions,
investigating alternative fabrication techniques, and studying the compatibility of these gears
with other materials and systems.

The project "Design, Fabrication, and Analysis of Aluminium Titanium Diboride Gear"
shows considerable promise for future applications. By employing rigorous design,
fabrication, and analysis methods, it indicates potential benefits across multiple industries.
The utilization of aluminium titanium diboride in gear production suggests improved
performance and durability, offering opportunities for advancements in various sectors such
as automotive and aerospace.

8
DESIGN, FABRICATION AND ANALYSIS OF Al-TiB2 GEAR

CHAPTER- 8
REFERENCES
 [1] Pawar PB, Utpat AA. Development of aluminium based silicon carbide particulate
metal matrix composite for spur gear. Procedia Materials Science. 2014; 6:1150-6.

 [2] Pawar PB, Utpat AA. Analysis of composite material spur gear under static loading
condition. Materials Today: Proceedings. 2015; 2(4-5):2968-74.

 [3] Saravanan SD, Kumar MS. Effect of mechanical properties on rice husk ash reinforced
aluminum alloy (AlSi10Mg) matrix composites. Procedia Engineering. 2013; 64:1505-
13.

 [4] Devi NC, Mahesh V, Selvaraj N. Mechanical characterization of aluminium silicon

carbide composite. International Journal of Applied Engineering Research. 2011;
1(4):793-9

 . [5] Suragimath MP, Purohit DG. A study on mechanical properties of aluminium alloy
(LM6) reinforced with SiC and fly Ash. IOSR Journal of Mechanical and Civil Engineering.
2013; 8(5):13-8.

 [6] Hassan AR. Contact stress analysis of spur gear teeth pair. World Academy of
Science, Engineering and Technology. 2009; 3(10):1279-84.

 [7] Hwang SC, Lee JH, Lee DH, Han SH, Lee KH. Contact stress analysis for a pair of
mating gears. Mathematical and Computer Modelling. 2013; 57(1- 2):40-9.

 [8] Tiwari SK, Joshi UK. Stress analysis of mating involute spur gear teeth. International
Journal of Engineering Research & Technology. 2012; 1(9):1-12.

 [9] Khan MJ, Mangla A. Contact stress analysis of stainless steel spur gears using finite
element analysis and comparison with theoretical results using hertz theory.
International Journal of Engineering Research and Applications. 2015; 5(4):10-8.

 [10] Quadri SA, Dhananjay RD. Contact stress analysis of involute spur gear under static
loading. International Journal of Scientific Research Engineering & Technology. 2015;
4(5):593-6.

 [11] Kolambe CE, Barde DR. Study of helical gear analysis using FEA software.
International Journal of Engineering Science and Computing. 2016; 6(3):2136- 41.

 [12] Rahate HP, Marne RA. Finite element analysis of composite spur gear for contact
stress. International Journal of Advance Research in Science and Engineering. 2016;
5(1):231-6.

 [13] Patil SS, Karuppanan S, Atanasovska I. Experimental measurement of strain and

stress state at the contacting helical gear pairs. Measurement. 2016; 82:313-22.

 [14] Jebur AK, Khan IA, Nath Y. Numerical and experimental dynamic contact of rotating
spur gear. Modern Applied Science. 2011; 5(2):254-63.

9
DESIGN, FABRICATION AND ANALYSIS OF Al-TiB2 GEAR

 [15] Chor PM, Pillai P. Spur gear contact stress analysis and stress reduction by
experiment method. International Journal of Engineering Research and General Science.
2015; 3(3):126-35.

 [16] Rahate HP, Marne RA. Contact stress analysis of composite spur gear using photo-
stress method and finite element analysis. International Research Journal of Engineering
and Technology. 2016; 3(7):540-5.

 [17] Karaveer V, Mogrekar A, Joseph TP. Modeling and finite element analysis of spur
gear. International Journal of Current Engineering and Technology. 2013; 3(5):2104-7.

(Guide)

AMITH KUMAR S N

Assistant Professor,

Department of Mechanical Engineering,

Dr. Ambedkar Institute of Technology

10