Ghulam Ishaq Khan Institute of

Engineering Sciences and Technology,

Topi.

Manufacturing (ME-353) CEP

REPORT

Design and Manufacturing of Helical

Gear for Marine Propulsion System

Abdullah Wali 2021041

Ashar Tanveer 2021112
Hasham Ahmed Khawaja 2021215
Table Of Content
Introduction................................................................................................................................... 3

Product Description ...................................................................................................................... 3

Product Selection .......................................................................................................................... 3

Material Selection ......................................................................................................................... 4

Mechanical Manufacturing Process.............................................................................................. 5

Calculations:.............................................................................................................................. 5

Lathe Machine: ....................................................................................................................... 10

Milling Machine:..................................................................................................................... 10

Alternative Manufacturing Process ............................................................................................ 13

Cost Analysis .............................................................................................................................. 14

Ergonomics and Human Factor .................................................................................................. 14

References……………………………………………………………………………………....14

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1. Introduction
This report explores the design, manufacturing, and material selection processes involved in
creating high-quality helical gears for a marine propulsion system. Helical gears were chosen for
their superior meshing characteristics, reduced noise levels, and higher load -bearing capacity
compared to other gear types. The report covers detailed calculations, CAD modeling, and
mechanical manufacturing steps, including lathe and milling machine operations. Alternative
manufacturing processes such as casting, 3D printing, laser cutting, shaping, and waterjet cutting
are also discussed, highlighting their pros and cons in gear production.

2. Product Description
The helical gear is a type of cylindrical gear with helically shaped teeth that are cut at an angle to
the gear axis. This design offers several advantages, including smoother and quieter operation
compared to spur gears, along with improved load -bearing capacity and alignment. These
qualities make helical gears well-suited for applications where precision, reliability, and reduced
noise levels are essential, as is the case of a propulsion system of a marine boat.

3. Product Selection:
The selection of helical gear was based on several factors. Firstly, helical gears provide improved
meshing characteristics and reduced noise levels compared to other gear types, which is crucial
for maintaining the vessel’s operational stealth and precision. Secondly, helical gears offer
higher load-carrying capacity and smoother torque transmission, ensuring the drive chain can
handle the diverse operating conditions encountered by the vessel. Lastly, the manufacturability
of helical gears was considered, considering factors such as material selection, machining
processes, and cost-effectiveness to ensure the gears meet performance requirements while
remaining feasible for production. This project report will delve into the detailed design,
manufacturing steps, material selection criteria, and testing processes involved in creating high-
quality helical gears.

Property Spur gear Helical gear Bevel Gear

Noise level High Low Moderate
Load carrying capacity Moderate to High High Moderate
Smoothness of operation Average Smooth Smooth
Axial thrust Present (unidirectional) Present (reduced) Minimal

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4. Material Selection
Choosing the right materials for gears involves considering several key properties. Strength is
crucial for handling the loads gears encountered without breaking. Hardness helps resist wear
and maintain shape under pressure. Wear resistance is important for long -term durability and
efficient operation. Corrosion resistance is vital in harsh environments to prevent damage over
time. Weight impacts performance and efficiency, especially in applications where lighter
components are beneficial. Cost and machinability influence production feasibility and expenses.
Heat resistance ensures gears can operate reliably at elevated temperatures without losing
effectiveness. Taking these factors into account helps ensure gears perform well, last long, and
remain cost-effective in their intended uses.
Property Mild steel HSS Aluminum
Strength Moderate High Moderate
Hardness Moderate High low
Ductility High low high
Corrosion resistance Low low High

Weight Moderate moderate Low

Cost Low high high
Machinability Good good Excellent
Wear resistance Moderate high Low
Heat resistance Moderate high low

Property Mild steel HSS Aluminum

Tensile strength 450 Mpa 900Mpa 600Mpa
Youngs modulus 200 Gpa 210 Gpa 70Gpa
Hardness (Hb) 160 HB 66 HRC 90 HB

Mild steel is a good option for making due to its moderate strength, cost-effectiveness, ease of
machining, and shock absorption capabilities. These properties make it a practical and reliable
choice for components that need to withstand forces and stresses during operation while
remaining affordable and easy to manufacture.

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5. Mechanical Manufacturing Process
The mechanical manufacturing process includes the following steps,
5.1. Calculations:
The manufacturing of helical gear requires the calculation of different parameters of gears. These
calculations were done on an Excel sheet with the help of formulas quoted from books and
research papers.
Formulas
1. Pitch diameter D = N/Pd where N= no. of teeth, Pd= diametral pitch,
2. Gear ratio = Ndriving/Ndriven,
3. Pressure angle α, Standard pressure angle for the gears is 20,
4. Helix Angle β=arctan(L/(π*D)),
5. Module m=D/N, where D=pitch diameter, N =number of teeth,
6. Tooth thickness t=π*m,
7. Root fillet radius
8. Shaft angle = sum of helix angle of both gears
9. Outside Diameter Do=D+2m
10. Gear Lead = (Pitch diameter * π)/(tan(β))
11. Table lead = 240mm
12. Gear Ratio = Gear Lead / Table Lead

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Excel sheet:

Figure 1 Required Input

Figure 2 Calculations of Helical Gear

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5.2. CAD Model:
According to the calculations, we have obtained a 3D CAD model. These 3D models of helical gear are
designed by SOLIDWORKS. Both gear parameters are truly based on calculations.
Pinion

Figure 3 Drawing of Pinion

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Gear

Figure 4 Drawing of Gear

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Assembly

Figure 5 Assembly of helical gear

Figure 6 Final Assembly

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5.3. Lathe Machine:
After selecting the suitable configuration
material, we first obtain the required diameter of
the raw mild steel with the help of the lathe
machine. The maximum diameter of mild steel
available in the lab was 30 and 50 mm.
According to the calculation and CAD model,
the diameters required for two gears were 19mm
and 49mm.
Rotational speed (N) = 100 rpm
Final Diameter of part (Df) = 19 mm
Original Diameter of part (Do) =30 mm
Feed (f)= 0.4 mm per rev
Length of part (L) = 50 mm
Figure 7 Turning

Formula Value
Cutting speed at cylinder surface (v) v 9424 mm/min
N=
𝜋 ∗ Do
Feed rate (fr) 𝑓𝑟 = 𝑁 ∗ 𝑓 40 mm per min
Time to machine (Tm) 𝜋 ∗ 𝐷𝑜 ∗ 𝐿 1.25 min
𝑇𝑚 =
𝑓∗𝑣
Material removal rate (Rmr) 𝑅𝑚𝑟 = 𝑣 ∗ 𝑓 ∗ 𝑑 20,700 mm3/s

Figure 8 Blank

5.4. Milling Machine:

Once the diameter is obtained, through milling we manufacture helical gear with the help of a
Milling machine. The process required adjustment of the appropriate gear ratio. However,
according to the tooth required on the gear we also select a cutter. The bed of the milling
machine was set at 25 degrees as the helical angle was calculated.
Rotational speed (N) =100 rpm
Feed (f) = 0.4 mm per revolutions

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Number of teeth (nt) = 14
Diameter of cutter (D) = 24mm
Depth of cut (d) = 2mm
Width = 4mm
Length = 14mm

Formula Value
Area of cut (A) 𝐴 = √𝑑(𝐷 − 𝑑) 6.63 mm2
Feed rate (fr) 𝑓𝑟 = 𝑁 ∗ 𝑛𝑡 ∗ 𝑓 560 mm per min
Material removal rate (Rmr) 𝑅𝑚𝑟 = 𝑤 ∗ 𝑑 ∗ 𝑓𝑟 4480 mm3/s
Time to machine (Tm) 𝐿+𝐴 0.516 min
𝑇𝑚 =
𝑓𝑟

Number of teeth Cutter Number

14-16 2
24-28 5

Gear Ratios
Gear Ratio 2:1
Gear adjustment Ratio (19mm) 0.65
Gear adjustment Ratio (49mm) 1.33

Figure 9 Gear Ratio of Milling Machine Figure 10 Cutting of helical gear Figure 11 Helical gear
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5.5. Drilling:
The available shaft in the lab was 10mm. That’s why the through hole was machined in both
gears of 10mm with the help of a lathe machine.
Rotational speed (N) =100rpm
Feed (f) = 0.4 mm per revolutions
Diameter of drill bit (D) = 10mm
Point angle (𝜃) = 20 degrees

Formula Value
Feed rate (fr) 𝑓𝑟 = 𝑓 ∗ 𝑁 40 mm per min
Area (A) 𝜃 28.4 mm2
𝐴 = 0.5 ∗ 𝐷 ∗ tan⁡(90 − )
2
Time to machine (Tm) 𝑑 0.325 min
𝑇𝑚 =
𝑓𝑟
Material removal rate (Rmr) 𝑅𝑚𝑟 = 𝐴 ∗ 𝑓𝑟 1136 mm3/min

5.6. Lathe machine (Parting tool):

A parting tool used in a lathe machine for cutting gears is a specialized cutting tool designed to
create the gear teeth profile on a gear blank.

Figure 12 Parting

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6. Alternative Manufacturing Process
Helical gear can be manufactured with the help of various methods. Some of them are discussed
below:
6.1. Casting:
Pros: Complex parts can be manufactured easily and with great speed in comparison with other
processes. It is also cost-effective.
Cons: Relatively poor dimensional consistency and accuracy. Additionally, poor working
environments with high-temperature, dust, and high labor intensity.
6.2. 3D printing/ Additive manufacturing:
Pros: Allows for complex geometries, customization, and rapid prototyping.
Cons: Limited in terms of material selection, may have lower strength and durability compared
to traditionally manufactured gears, and surface finish may not be as smooth.
6.3. Laser Cutting:
Pros: Can be used for prototyping and small batch production, a relatively fast process.
Cons: May have lower precision compared to machining methods, limited to certain materials
and thicknesses.
6.4. Shaping:
Pros: Suitable for small batch production, relatively low cost.
Cons: Slower than other methods, may have lower precision and surface finish compared to
milling.
6.5. Waterjet Cutting:
Pros: It is a cold-cutting process that includes high accuracy and high-quality cutting.
Cons: They often take longer time as compared to traditional methods. Low-quality waterjet
orifices are known to break down, which could result in a loss of time and productivity and
disrupt the cutting process.

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7. Cost Analysis
Pinion 33g
Gear 158g.
Wast material 300g

Mild steel RS 240 per kg

High Speed Steel 2000 per kg
Aluminum 720 per kg

Material Pinion Gear Waste Total

Mild steel 8 38 72 118
HSS 66 316 600 982
aluminum 24 114 216 354

8. Ergonomics and Human Factor

8.1. Workplace Safety:
Ensure that all manufacturing processes adhere to safety standards to prevent accidents and
injuries. Provide necessary safety gear like goggles, gloves, and ear protection due to the noise
generated during machining.
8.2. Physical Ergonomics:
Design workstations and machinery layouts ergonomically to minimize strain and fatigue on
workers. Consider factors such as height-adjustable workbenches, proper lighting, and
comfortable seating to promote a healthy working environment.
8.3. Training and Skill Development:
Conduct training sessions to educate workers on machine operation, safety protocols, and quality
standards. Skill development programs can enhance efficiency and quality in manufacturing
processes.

9. References
1. https://openoregon.pressbooks.pub/manufacturingprocesses45/chapter/unit-2-speed-and-
feed/
2. ANSI/AGMA 1012-G05. (2005). Gear Nomenclature, Definitions of Terms with
Symbols. American Gear Manufacturers Association.
3. Machinery Handbook, 31st Edition. (2016). Industrial Press Inc.
4. Shigley’s Mechanical Engineering Design. 10th Edition
5. Fundamental of modern manufacturing materials, process and systems, 7th edition

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