Dr. Ambedkar Institute of Technology.

DEPARTMENT OF MECHANICAL ENGINEERING

PROJECT WORK PHASE – II (18MEP78)

Design, Fabrication And Analysis Of AlTiB2 Spur Gear

Submitted by

Group Members :: 1) Ritik Prakash 1DA20ME069.

2) Rohan T 1DA20ME070.
3) Shahbaz H Doddamani 1DA20ME077.
4) Mohammed Abuzar B 1DA21ME425.

Under The Guidance Of

Prof. AMITH KUMAR S N
1.1 History of Composites
• From the ancient times, builders, artisans, engineers and manufacturers continued to develop
composites of a wider array of materials for more sophisticated applications. The advent of
the composites as a distinct classification of materials began during the mid-20th century with
the manufacturing of deliberately designed and engineered multiphase composites such as
fiberglass-reinforced polymers.
• In the early 1900’s, chemical advances drove the development of plastics. Materials such as
vinyl, polystyrene, phenolic and polyester were created and reinforcement to provide strength
and rigidity.
• In 1961, the first carbon fiber was patented and several years later, became commercially
available.
• Carbon fibers improved thermoset part stiffness to weight ratios, for use in even more
applications such as aerospace, automotive, sporting goods, and consumer goods.
• Today, composites research attracts grants from governments, manufacturers and universities.
These investments allow innovation to accelerate.
• Specialized companies, such as aerospace composite companies, will find a place in the
industry. Other materials such as environmentally-friendly resins incorporating recycled
plastics and bio-based polymers meet the demand for stronger, lighter and environmentally
friendly products.
• By this we can say composites will be the future materials for all applications
1.2 Classification of Composites
Metal-matrix composites are those where metals
or alloys are used as matrix materials, as the name
implies. Metals used are usually ductile in nature
and is reinforced with strong and low density
materials of all shapes-fibers, whiskers and
particulate. Such combinations help in obtaining
materials with improved stiffness, abrasion
resistance, creep resistance, thermal conductivity
and dimensional stability.

Example: Aluminum Metal Matrix Composite Reinforced with TiB2

 Aluminium 2011
 Aluminum 2011 is a popular alloy within the aluminum-copper family, also known as Alloy 2011. It's a free-machining alloy with excellent
machinability, making it widely used in various industries, especially for parts requiring intricate shapes or precise tolerances. Here are some
key points about Aluminum 2011:

 Composition: Aluminum 2011 primarily consists of aluminum, copper, and a few other elements. The typical composition includes around
0.4% to 0.8% copper, 0.7% to 1.2% iron, less than 0.7% silicon, less than 0.15% zinc, and trace amounts of other elements.
 Machinability: One of the most significant advantages of Aluminum 2011 is its exceptional machinability. This property is due to its
composition and microstructure, which allows for efficient chip formation and removal during machining operations. It can be easily turned,
drilled, milled, and tapped, making it ideal for applications where intricate parts with tight tolerances are required.
 Strength and Hardness: While Aluminum 2011 offers good mechanical properties, it is not as strong as some other aluminum alloys, such as
2024 or 7075. However, it still provides adequate strength for many applications, especially when combined with its excellent machinability.
 Applications: Aluminum 2011 is commonly used in the manufacturing of various precision components, such as screw machine parts, fittings,
couplings, and valves. Its ease of machining makes it suitable for high-speed machining processes, leading to increased productivity and cost-
effectiveness in manufacturing operations.
 Anodizing: Aluminum 2011 can be successfully anodized to improve its corrosion resistance and surface finish. Anodizing is an
electrochemical process that forms a protective oxide layer on the surface of the aluminum, enhancing its durability and appearance.
 Weldability: While Aluminum 2011 is generally considered to have poor weldability compared to other aluminum alloys, it can be welded
using conventional methods such as TIG (tungsten inert gas) or MIG (metal inert gas) welding. However, welding may affect its mechanical
properties, and precautions should be taken to minimize the risk of cracking or other defects.
 Introduction
• Aluminium [Al 2011] alloy materials, also known as metal matrix composites, are blends of various materials. These composites
involve combining two or more materials to create resulting materials with specific or enhanced design properties. Aluminium
alloy composite materials find extensive use across various applications, including engineering structures, electronics, and
sporting goods, due to their lightweight nature and superior properties [1].

• The project titled "Design, Fabrication, and Analysis of Aluminium Titanium Diboride (Al- TiB2) Spur 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 analyze
spur 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.
• In the fabrication phase, advanced manufacturing techniques like In-Situ stir casting are employed to produce spur 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.
 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.
 LITERATURE SURVEY
Title Years
Spur gear tooth stress
analysis and stress
reductio using stress 2006
reducing geometrical
features
aluminium alloy (LM6)
Suragimath MP, Purohit properties of aluminium
reinforced with SiC and 2013
fly Ash
Contact Stress Analysis
2009
of Spur Gear Teeth Pair
Focus of the
Authors
paper
Made an extensive
Manoj Hariharan analysis on composite
spur gears
studied on mechanical
DG alloy (LM6) reinforced
with SiC and fly Ash
The article discusses
contact stress between
two spur gear teeth in
Ali Raad Hassan
different contact
positions, representing a
pair of mating gears

Effect of Mechanical
Properties on Rice Husk
Ash Reinforced Aluminum 2013
alloy (AlSi10Mg) Matrix
Composites.
Development of Aluminium
Based Silicon Carbide
Particulate 2014
Metal Matrix Composite for
Spur Gear
Developed metal matrix
composites by varying
rice husk ash
percentage and
concludes that with
increase in percentage
Saravanan and Kumar of rice husk ash in
metal matrix
composites will
increase its mechanical
properties.
Authors has done FEA
of gear using ANSYS
14.0 and concluded that
composite gears offer
Pawar and Utpat improved properties
over steel alloys and
can be replaced with
metallic gears.

Contact stress analysis for a
2013
pair of mating gears
Contact Stress Analysis of
Stainless Steel Spur Gears
using Finite Element
2015
Analysis and Comparison
with Theoretical Results
using Hertz Theory
presents a contact stress analysis
for a pair of mating gears during
rotation and performed contact
stress analysis for spur and
Hwang et al helical gears between two gear
teeth at different contact
positions during rotation.
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
Khan and Mangla analyzed using ANSYS. It is
found that the results obtained
from theoretical method and
FEA are comparable with each
other.
 Methodology DESIGN PHASE

The methodology in a project refers to the systematic and

MATERIAL SELECTION
structured approach that guides the planning, execution, and
completion of the project. A well-defined methodology helps
ensure that the project is carried out efficiently, meets its
objectives, and delivers the desired outcomes.
The methods being followed throughout the project is as FABRICATION PROCESS
follows:

ANALYSIS AND
PERFORMANCE
EVALUATION
These mentioned methods are implemented during the course
of project and will be followed strictly to achieve the desired
outcomes
DOCUMENTATION AND
REPORTING
 TIME ESTIMATION

Estimating the time required for a project is a critical aspect of project management. Accurate time estimates help
in planning, resource allocation, and ensuring that the project stays on track. The time estimation for the above
mentioned project is as follows:

Sl no Task Start date End date Total duration

Thanks
!