INTRODUCTION

"In Shanthi Gears, they have a tie-up with the Murugappa Group and possess a wide array of
machinery in the company. I have learned about the various types of gears such as spur, helical,
bevel, and chain gears. Shanthi Gears Limited (SGL) is an industrial gearing solutions company
that began manufacturing gears for the textile industry in 1969. In 1972, the company was
incorporated as a private limited company, Shanthi Gear Products Pvt. Ltd., taking over the
partnership firm established in 1969 by Shri Subramaniam. SGL operates manufacturing facilities
in and around Coimbatore, Tamil Nadu, which includes a foundry."

1
 OBJECTIVE

• What are types of gear

• what machinery are made for gear

• heat treatment process

• types of gear box

• suppliers

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WORKFLOW DIAGRAM GEAR BOX ASSEMBLY

COLLECT THE DATA

DRAW A DIAGRAM GIVEN

DATA

CREATE A GIVEN CONTRAINT

PART DIAGRAM

Assemble the part given

constraint

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 SPUR

FIG 4.0
Spur gears transmit power between parallel shafts. As the gears rotate, the teeth engage and
transmit torque from the driving gear to the driven gear. The direction of rotation of the driven
gear is always opposite to that of the driving gear, and the speed of the driven gear is determined
by the gear ratio.
\[ R = \frac{N_1}{N_2} \]
Where:
- \( N_1 \) is the number of teeth on the driving gear (also called the "driver").
- \( N_2 \) is the number of teeth on the driven gear (also called the "driven").
This formula is fundamental because it determines how the rotational speed and torque are
transmitted between gears. For example, if gear 1 (with \( N_1 \) teeth) is driving gear 2 (with \(
N_2 \) teeth), then for every rotation of gear 1, gear 2 will rotate \( R \) times.
Additionally, some other formulas related to spur gears include:
1. Pitch Diameter (\( D \)):
\[ D = \frac{N}{P} \]
Where:
- \( N \) is the number of teeth on the gear.
- \( P \) is the diametral pitch, which represents the number of teeth per unit length of the gear's
pitch diameter.
2. Pitch Circle Diameter (\( D_p \)):
\[ D_p = \frac{N}{\text{DP}} \]
Where:
- \( D_p \) is the pitch circle diameter.
- \( N \) is the number of teeth on the gear.
- \(\text {DP} \) is the circular pitch, which represents the distance between corresponding points

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 HELICAL GEAR
Spur gears are cylindrical components with teeth that are used in industrial equipment to control
speed, power, torque, and transfer mechanical motion.

FIG 5.0
The formulas for calculating various parameters of helical gears depend on the specific
requirements and characteristics of the gear system, such as the number of teeth, pitch
diameter, helix angle, and module (a measure of the size of the gear teeth).
Here are some fundamental formulas related to helical gears:
1. Pitch Diameter (D):
\[D = \frac{N}{m}\]
Where:
- \(D\) is the pitch diameter
- \(N\) is the number of teeth
- \(m\) is the module
2. Module (m):
\[m = \frac{D}{N}\]
3. Helix Angle (\(\gamma\)):
\[\tan(\gamma) = \frac{P}{\pi \cdot D}\]
Where:
- \(P\) is the axial pitch (distance between consecutive teeth along the helix)
4. Axial Pitch (P):
\[P = m \cdot \pi \cdot \cos(\gamma)\]
5. Normal Pitch (Pn):
\[Pn = \frac{\pi \cdot D}{\cos(\gamma)}\]
6. Lead (\(L\)):
\[L = P \cdot N\]

5
 WORM GEAR
A worm gear is a type of gear configuration consisting of a worm (a cylindrical screw and a
worm wheel (a type of gear). The worm resembles a screw thread, while the worm wheel
resembles a standard spur gear, but with teeth arranged in a helical shape.

FIG6.0
1. **Pitch Diameter of Worm Gear (Dw):**
\[D_w = \frac{Z_w \cdot m}{\cos(\beta)}\]

Where:
- \(D_w\) is the pitch diameter of the worm gear
- \(Z_w\) is the number of teeth on the worm gear
- \(m\) is the module of the worm
- \(\beta\) is the lead angle of the worm

2. **Lead Angle (\(\beta\)):**

\[\tan(\beta) = \frac{P}{\pi \cdot D}\]

Where:
- \(\beta\) is the lead angle
- \(P\) is the axial pitch (distance between consecutive threads)
- \(D\) is the pitch diameter of the worm

3. **Axial Pitch (P):**

\[P = m \cdot \pi \cdot \cos(\beta)\]

4. **Module (m):**
\[m = \frac{D_w}{Z_w \cdot \cos(\beta)}\]

5. **Lead (L):**
\[L = P \cdot Z_w\]

These formulas provide basic parameters for worm gear design and calculation.
Depending on specific requirements and considerations such as tooth profile, contact
ratio, and efficiency, additional calculations may be necessary for a comprehensive
design. It's crucial to ensure that the chosen parameters meet the functional

6
 CHAIN GEAR

FIG 7.0
The thread in a tailstock refers to the threaded portion of the quill or spindle that allows for the
attachment of various tooling or accessories. Tailstock threads are commonly standardized to
facilitate interchangeability and compatibility with different types of tooling.
If by "chain gear" you're referring to a sprocket and chain system, there isn't a single formula to
describe the entire system, as it involves the interaction between the sprocket and the chain.
However, I can provide you with some basic formulas related to sprockets and chains:

1. Pitch Diameter of Sprocket (D):

\[D = \frac{N}{P}\]

Where:
- \(D\) is the pitch diameter of the sprocket
- \(N\) is the number of teeth on the sprocket
- \(P\) is the pitch of the chain

2. Pitch of the Chain (P):

\[P = \frac{L}{N}\]

Where:
- \(P\) is the pitch of the chain
- \(L\) is the length of a certain number of chain links

3. Speed Ratio (SR):

\[SR = \frac{N_1}{N_2}\]

Where:
- \(N_1\) is the number of teeth on the driving sprocket
- \(N_2\) is the number of teeth on the driven sprocket

These formulas provide some basic calculations for sprockets and chains. Depending on your
specific application and requirements, you may need additional formulas to calculate parameters
such as chain tension, center distance between sprockets, and power transmission efficiency.

It's worth noting that sprocket and chain systems involve considerations beyond simple geometric
calculations, such as material selection, lubrication, and maintenance, which are crucial for the
proper functioning and longevity of the system.

7
 SPUR GEAR BOX

1. Location and Placement

- The studs should be clearly illustrated in the assembly drawing, indicating their precise
locations relative to the tailstock base and bed of the machine tool.
- Callouts or labels can be used to identify each stud and its corresponding position.
2. Thread Specifications:
- Detail the specifications of the studs' threads, including the thread size, pitch, and length. This
information is essential for ensuring compatibility with nuts or threaded holes in the machine bed.
- Specify the thread type (e.g., UNC, UNF, metric) and any special threading requirements.
3. Dimensions:
- Provide dimensions for the studs, including their diameter and length. These dimensions should
accurately represent the physical characteristics of the studs.

FIG 8.0
Helical gear box
Bevel helical gearboxes are characterized by curved teeth enclosed within a cone -shaped based at
device edge . by creating rotating motion between non-parallel shafts, this design achieves a stable
and silent operation. As is customary, the spiral teeth mesh with other helical gears.

FIG 8.1

8
 WORM GEAR BOX
A worm gear box, also known as a worm gearbox or worm reduction gearbox, is a type of gearbox that uses
a worm and worm wheel (also called a worm gear) to transmit power between perpendicular shafts. Here's
an overview:

1. Worm: The worm is a cylindrical screw with a helical thread that meshes with the teeth of the worm
wheel. It is the driving component of the system and is typically mounted on one shaft.

2. Worm Wheel (Worm Gear): The worm wheel is a gear wheel with teeth arranged in a helical pattern
around its circumference. It meshes with the worm and is mounted on the shaft perpendicular to the worm.
The worm wheel is the driven component of the system.

4. Advantages:
- High Reduction Ratio: Worm gearboxes can achieve high reduction ratios with a single gear stage,
reducing the speed of the output shaft while increasing torque.
- Self-Locking: Worm gearboxes are inherently self-locking, meaning the worm can prevent the worm
wheel from turning backward. This property makes worm gearboxes ideal for applications where holding
the load in position without power is necessary.
- Compact Design: Worm gearboxes have a compact and space-saving design compared to other types of
gearboxes with similar reduction ratios.

5. Applications**:
- Worm gearboxes are widely used in various industrial applications, including conveyor systems,
packaging machinery, lifting equipment, and automotive mechanisms.
- They are commonly employed in situations where high torque and low speed are required, such as in
winches, hoists, and lifts.

FIG 9.0
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 SHANTHI GEAR USED MACHINE ARE

LATHE

FIG 10.0
A lathe is a machine tool used in machining operations to shape metal, wood, or other materials by rotating
the workpiece against cutting tools. Lathes come in various sizes and configurations, ranging from small
benchtop models to large industrial machines. Here's an overview of the key components and functions of
a lathe:

1. Bed: The bed is the horizontal base of the lathe, typically made of cast iron, that supports all the other
components of the machine. It provides rigidity and stability to the lathe.

2. Headstock: The headstock is located at one end of the bed and contains the main spindle, which rotates
the workpiece. It also houses the gearing mechanism for controlling spindle speed and may include a chuck
or other workholding device.

CNC LATHE

.
FIG 10.1

A CNC (Computer Numerical Control) lathe is a type of lathe machine that is controlled by a computer
program to automate and precisely control the machining process. CNC lathes are widely used in
manufacturing industries for producing complex and precision parts with high efficiency. Here's an
overview of CNC lathes and their key feat

10
 MILLING

FIG 10.2

Milling is a machining process that uses rotary cutters to remove material from a workpiece by
advancing a cutter into the workpiece at a certain direction. Milling machines are the tools used to
perform milling operations, and they come in various sizes and configurations. Here's an overview
of milling and its key aspects:

VMC MILLING

VMC stands for Vertical Machining Center. It's a type of milling machine that operates vertically,
with the spindle mounted vertically parallel to the column face. Here's an overview of VMCs and
their key feature

FIG 10.3

11
 HOBBLING MACHINE

FIG 10.4
A Hobbing machine is a specialized machine tool used in gear manufacturing to produce gears, splines, and
sprockets with teeth. The process of cutting gear teeth using a Hobbing machine is called Hobbing. Here's
an overview of Hobbing machines and their key features:
1. Hobbing Process: Hobbing is a gear cutting process that uses a rotating cutting tool called a hob to
generate the teeth of the gear. The hob is mounted on a hob arbor and is fed into the workpiece blank, which
is typically a rotating cylindrical piece of metal. As the hob rotates and advances into the workpiece, it cuts
the teeth into the blank, creating the desired gear profile.

Hobbing cnc

"CNC Hobbing" refers to the use of Computer Numerical Control (CNC) technology in Hobbing machines.
CNC Hobbing machines are equipped with CNC controls that automate and precisely control the Hobbing
process. Here's an overview of CNC Hobbing and its key aspects:

FIG10.5

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 Slotting machine

FIG 10.6
A slotting machine is a machine tool used to produce slots, keyways, grooves, and other internal
or external features in workpieces. Slotting machines are commonly used in machining operations
to create slots in components such as gears, pulleys, shafts, and machine tool components. Here's
an overview of slotting machines and their key features:

1. Vertical Configuration: Slotting machines are typically vertical machines, where the cutting tool
moves vertically up and down to produce the desired slot or groove in the workpiece. The
workpiece is held stationary on a table or fixture, and the cutting tool is mounted on a ram that
moves vertically.

2. Ram and Tool Head: The ram is a vertical column or arm that carries the cutting tool holder and
can move vertically to control the depth of cut. The tool head is mounted on the ram and holds the
cutting tool, which is typically a single-point cutting tool or a slitting saw.

3. Feed Mechanism: Slotting machines may have manual, automatic, or hydraulic feed
mechanisms that control the movement of the ram and the cutting tool. Manual slotting machines
require manual operation by the operator, while automatic and hydraulic slotting machines can
feed the tool automatically and control the cutting speed and depth.

4. Workpiece Holding: The workpiece is held securely on a table or fixture during the slotting
operation. The table may have T-slots or other clamping mechanisms to hold the workpiece in
place and ensure stability during machining.

5. Cutting Tools: Slotting machines use various types of cutting tools, including single-point
cutting tools, slitting saws, and broaches, depending on the specific application and the desired
slot geometry. The cutting tool is mounted on the tool holder and is fed into the workpiece to
remove material and create the slot or groove.

6. Applications: Slotting machines are used in various industries, including automotive, aerospace,
machinery manufacturing, and tool and die making, to produce slots, keyways, grooves, and other
internal or external features in workpieces. They are commonly used in conjunction with

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 HEAT TREATMENT PROCESS USE IN GEAR

Heat treatment processes play a crucial role in the manufacturing of gears, as they can significantly
improve the mechanical properties and performance of the gears. Here are some common heat
treatment processes used in gear manufacturing:

1. Hardening: Hardening is a heat treatment process used to increase the hardness and strength of
the gear material. The gear is heated to a critical temperature (usually above its transformation
temperature) and then rapidly cooled, typically by quenching in oil, water, or polymer. This rapid
cooling causes the formation of a hardened microstructure, such as martensite, which provides
increased hardness and strength.

2. Tempering: Tempering is often performed after hardening to reduce the brittleness and improve
the toughness of the hardened gear material. The hardened gear is heated to a lower temperature
and held for a specific time, then cooled slowly. This process allows for the transformation of
some of the martensite into less brittle microstructures, such as tempered martensite or bainite,
while retaining the desired hardness and strength.

3. Annealing: Annealing is a heat treatment process used to soften the gear material and relieve
internal stresses. The gear is heated to a temperature below its transformation temperature and then
cooled slowly in the furnace. This process allows for the recrystallization and homogenization of
the microstructure, resulting in improved machinability, ductility, and dimensional stability.

4. Carburizing: Carburizing is a surface hardening process used to increase the hardness and wear
resistance of the gear teeth. The gear is heated in a carbon-rich atmosphere, such as gas or liquid
carburizing, at high temperatures for an extended period. Carbon atoms diffuse into the surface
layers of the gear material, forming a hardened case layer with increased carbon content. The gear
is then quenched and tempered to achieve the desired hardness and toughness.

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 FURNACE USING GEAR
In industrial settings, furnaces are commonly used in the heat treatment processes for gears. Here's
how furnaces are utilized in gear manufacturing:

1. Heat Treatment Furnaces: Furnaces are used for various heat treatment processes such as
hardening, tempering, annealing, carburizing, nitriding, and induction hardening, which were
discussed earlier. These processes involve heating the gears to specific temperatures and then
cooling them under controlled conditions to achieve the desired mechanical properties.

2. Batch Furnaces: Batch furnaces are commonly used for small to medium-scale gear
manufacturing operations. Gears are loaded into trays or baskets and placed inside the furnace
chamber. The furnace heats the gears to the required temperature and holds them at that
temperature for a specified time before cooling.

3. Continuous Furnaces: Continuous furnaces are used in high-volume gear production where a
continuous flow of gears is processed. Gears are fed into one end of the furnace and travel through
the heating and cooling zones on a conveyor belt or roller system. This allows for a continuous
and efficient heat treatment process.

4. Gas Atmosphere Furnaces: Gas atmosphere furnaces are equipped with controlled atmospheres,
such as nitrogen, hydrogen, or dissociated ammonia, to create specific gas environments for heat
treatment processes like carburizing and nitriding. These atmospheres help enhance the
effectiveness of the heat treatment and prevent oxidation or decarburization of the gears.

5. Vacuum Furnaces: Vacuum furnaces are used for heat treatment processes that require
controlled atmospheres with low oxygen levels or for processes where surface cleanliness and
minimal distortion are critical. Vacuum furnaces can be used for processes such as vacuum
carburizing, vacuum annealing, and vacuum brazing of gears.

15
CONCLUSION
In conclusion, gear manufacturing is a complex and multifaceted process that plays a vital role in
various industries, including automotive, aerospace, machinery manufacturing, and power
generation. Gears are essential components in countless mechanical systems, transmitting power
and motion efficiently and reliably.

Throughout this report, we have explored the key aspects of gear manufacturing, including design
considerations, material selection, machining processes, and heat treatment techniques. Here are
some key takeaways:

Overall, gear manufacturing requires a combination of advanced technology, engineering

expertise, and meticulous attention to detail. By understanding the principles and processes
involved in gear manufacturing, manufacturers can produce high-quality gears that meet the
demands of modern industrial applications.

As industries continue to evolve and demand higher performance from mechanical systems, gear
manufacturers must stay abreast of technological advancements and adopt innovative approaches
to meet the challenges of tomorrow. With ongoing research and development, the future of gear
manufacturing holds exciting possibilities for enhancing efficiency, reliability, and performance
across a wide range of applications.

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