![Team members
MUHAMMADASYRAF BIN ISMANIZAN [A167554]
- SECOND YEAR MECHANICAL ENGINEERING STUDENT
- Department of Mechanical & Manufacturing Engineering
Faculty of Engineering & Built Environment
Universiti Kebangsaan Malaysia
- Email: A167554@siswa.ukm.edu.my
MOHAMADSYAFIQ SALMAN BIN AZMAN [A167681]
- SECOND YEAR MECHANICAL ENGINEERING STUDENT
- Department of Mechanical & Manufacturing Engineering
Faculty of Engineering & Built Environment
Universiti Kebangsaan Malaysia
- Email: A167681@siswa.ukm.edu.my](https://image.slidesharecdn.com/sunconegearsslide-200719152225/85/Suncone-gears-slide-4-320.jpg)
![Team members
Amier bazlie bin johari [A170279]
- SECOND YEAR MECHANICAL ENGINEERING STUDENT
- Department of Mechanical & Manufacturing Engineering
Faculty of Engineering & Built Environment
Universiti Kebangsaan Malaysia
- Email: A170279@siswa.ukm.edu.my
NURUL SYAZWANI BINTI SAHARI [A169841]
- SECOND YEAR MECHANICAL ENGINEERING STUDENT
- Department of Mechanical & Manufacturing Engineering
Faculty of Engineering & Built Environment
Universiti Kebangsaan Malaysia
- Email: A169841@siswa.ukm.edu.my](https://image.slidesharecdn.com/sunconegearsslide-200719152225/85/Suncone-gears-slide-5-320.jpg)
Suncone gears slide
- 1. BY: MUHAMMAD ASYRAF BIN ISMANIZAN (A167554) NURUL SYAZWANI BINTI SAHARI (A169841) AMIER BAZLIE BIN JOHARI (A170279) MOHAMAD SYAFIQ SALMAN BIN AZMAN (A167681) Department of Mechanical & Manufacturing Engineering Faculty of Engineering & Built Environment Universiti Kebangsaan Malaysia “MANUFACTURING PROCESSES OF GEARS”
- 2. With guidance from LECTURERS PROF DR.ANDANASTUTIMUCHTAR Dr.nabilah afiqah binti mohdradzuan DR.NASHRAH HANI BINTI JAMADON Department of Mechanical & Manufacturing Engineering Faculty of Engineering & Built Environment Universiti Kebangsaan Malaysia Email: [email protected] Department of Mechanical & Manufacturing Engineering Faculty of Engineering & Built Environment Universiti Kebangsaan Malaysia Email: [email protected] Department of Mechanical & Manufacturing Engineering Faculty of Engineering & Built Environment Universiti Kebangsaan Malaysia Email: [email protected]
- 3. WHAT ARE GEARS? 01 -Introduction about Gears/Cogwheel -Applications in industry HOW ITS MADE 02 -Explains how gears are made in the industry analysis 03 -Materials used in making the gears - Properties of the material conclusion 04 -Best method in manufacturing gears
- 4. Team members MUHAMMADASYRAF BIN ISMANIZAN [A167554] - SECOND YEAR MECHANICAL ENGINEERING STUDENT - Department of Mechanical & Manufacturing Engineering Faculty of Engineering & Built Environment Universiti Kebangsaan Malaysia - Email: [email protected] MOHAMADSYAFIQ SALMAN BIN AZMAN [A167681] - SECOND YEAR MECHANICAL ENGINEERING STUDENT - Department of Mechanical & Manufacturing Engineering Faculty of Engineering & Built Environment Universiti Kebangsaan Malaysia - Email: [email protected]
- 5. Team members Amier bazlie bin johari [A170279] - SECOND YEAR MECHANICAL ENGINEERING STUDENT - Department of Mechanical & Manufacturing Engineering Faculty of Engineering & Built Environment Universiti Kebangsaan Malaysia - Email: [email protected] NURUL SYAZWANI BINTI SAHARI [A169841] - SECOND YEAR MECHANICAL ENGINEERING STUDENT - Department of Mechanical & Manufacturing Engineering Faculty of Engineering & Built Environment Universiti Kebangsaan Malaysia - Email: [email protected]
- 6. — TONY BLAIR “I can only go one way. I’ve not got a reverse gear. ” Ref:https://www.azquotes.com/quotes/topics/gears.html QUOTE OF THE DAY
- 7. WHAT ARE GEARS? 01 “...a machine part which rotates that has either cut teeth or inserted teeth that combines with another toothed part in order to create and transmit torque...” - Wikipedia Ref: https://en.wikipedia.org/wiki/Gear
- 8. INTRODUCTION ABOUT GEARS ● Mechanism that engage together via teeth are called gears or some people might be familiar with the word, cogwheel. They are often used in machinery to transmit rotary motion from one shaft to another. ● Gears are commonly found on machines where they are generally, either mounted or sometimes connected to another parts through bases or even shafts. This is for them to be able to transmit the rotary motion as mentioned. ● Although gears are known as simple machines, they are a very important element in the world of engineering nowadays, and are usually identified by Mechanical Engineers. ● Gears are designated by two main characteristics or items which are the radius and the number of teeth they have. Ref:https://www.teachengineering.org/lessons/view/umo_challenges_lesson02 Ref:https://www.creativemechanisms.com/gears
- 9. RADIUS VS TEETH Different particular section of the gear has differently defined gear radius. But, the most relevant measurement for radius are these two, which are the root radius and addendum radius. Other terminology used in designing gears also includes Pitch, Tooth Thickness, Dedendum and Tooth root. Teeth in gears are very crucial as they determine if the pairing gears can mesh together. Hence, the Pitch must be the same for all mating pairs. The distance between the equivalent points of adjacent teeth are known as the Pitch. A good mesh between mating gears helps prevent slipping and can also increase efficiencies as well. RADIUS TEETH Ref:https://khkgears.net/new/gear_knowledge/abcs_of_gears-b/basic_gear_terminology_calculation.html Ref:https://gearsolutions.com/features/determining-gear-efficiency/
- 10. TYPES OF GEARS ● There are many types of gears invented to suit the needs of different machinery and to perform different functions. The most common ones are the helical gears, spur gears, straight and spiral bevel gears and also the hypoid gear. ● Gears has been classified through various methods in the industry. The most popular classification of different types of gears is by looking at different position of the gear axis. While on the other hand, the method of manufacturing the gear, the tooth profile and material used can also play a role in determining the type of the gear produced. ● The most common and widely used type of gear is the Spur Gear as they can achieve very high accuracy along with easy production processes ● There are also many other types of gears out there in the industry besides what has been mentioned above Ref:https://www.sciencedirect.com/science/article/abs/pii/1350630796000088 Ref:https://khkgears.net/new/gear_knowledge/introduction_to_gears/types_of_gears.html
- 11. SPUR GEARS ● Amongst all kind of gears, Spur gears are the most common type of gear ● The teeth are designed to be protruded outwards from its perimeter ● Powers are transmitted through shafts that are parallel in position. ● Disadvantages of using this gear includes noises being produced due to the teeth of gears colliding with each other. Photo courtesy Emerson Power Transmission Corp. Ref:https://www.rexnord.com/blog/articles/types-of-gears Ref:https://www.thomasnet.com/articles/machinery-tools-supplies/understanding-gears/ Ref:https://science.howstuffworks.com/transport/engines-equipment/gear2.htm
- 12. HELICAL GEARS ● Noise reduction can be obtained by ultilizing helical gears. The teeth tend to start at one end and gradually moves to the rest of the teeth as it rotates since they are cut at an angle ● Provides smooth operation alongside of less impact loading being applied on the teeth ● High cost of manufacturing due to the complexity cutting the teeth at an angle Photo courtesy Emerson Power Transmission Corp. Ref:https://www.rexnord.com/blog/articles/types-of-gears Ref:https://www.thomasnet.com/articles/machinery-tools-supplies/understanding-gears/ Ref:https://science.howstuffworks.com/transport/engines-equipment/gear2.htm
- 13. SPIRAL BEVEL GEARS ● Has the same teeth cutting like Helical gears to aid in noise reduction. ● Has better strength and oscillation compared to Straight Bevel Gear. ● Disadvantage with using Spiral Bevel Gear is regarding the axial thrust load.Hence, this gear needs a proper bearing location and firm support to it. Photo by Medital.com Ref:https://www.rexnord.com/blog/articles/types-of-gears Ref:https://www.thomasnet.com/articles/machinery-tools-supplies/understanding-gears/ Ref:https://www.medital.com/products/spiral-bevel
- 15. SPUR GEAR INSIDE THE GEARBOX OF A WASHING MACHINE TO SPIN THE TUB. Ref:https://home.howstuffworks.com/washer6.htm AS SIMPLE AS INSIDE THE MECHANISM OF A CLOCK. Video credits goes to :https://www.youtube.com/watch?v=lnTlYZ1JhM8
- 16. HELICAL GEAR USED IN HIGH SPEED APPLICATIONSUCH AS THESE TWO, GAS AND STEAMTURBINES as these gears are highly durable that they can withstand high load and also ensure less wear at any time given since the load are distributedover several teeth.
- 17. SPiral bevel GEAR Fighter jets with up to 16,000 rpm jet application. DEFENCE TANKS WITH HIGH POWER DENSITY. Ref:https://bevelgearsindia.com/applications/ Video credits goes to :https://www.youtube.com/watch?v=ckmh6FvHidQ Video credits goes to :https://www.youtube.com/watch?v=GaxMKNHwEeA
- 18. References: Mechanisms, C. (n.d.). Gears. Retrieved July 10, 2020, from https://www.creativemechanisms.com/gears Nair, S., Samarth, P., & Nair, S. (2020, April 25). What Are Gears and What Do They Do? - Lesson. Retrieved July 9, 2020, from https://www.teachengineering.org/lessons/view/umo_challenges_lesson02 Relly Victoria Petrescu - Narcisa Popescu, By, -, Relly Victoria Petrescu is a lecturer in the Department of Descriptive Geometry and Engineering Graphics at the University Politehnica of Bucharest., Petrescu, R., Is a lecturer in the Department of Descriptive Geometry and Engineering Graphics at the University Politehnica of Bucharest., . . . Is an assistant professor in the university’s in Department of Mechanisms and Robots. (2019, November 21). Relly Victoria Petrescu. Retrieved July 19, 2020, from https://gearsolutions.com/features/determining-gear-efficiency/
- 19. References: Basic Gear Terminology and Calculation. (n.d.). Retrieved July 6, 2020, from https://khkgears.net/new/gear_knowledge/abcs_of_gears- b/basic_gear_terminology_calculation.html Types of Gears: Free Gear Guide. (n.d.). Retrieved July 11, 2020, from https://khkgears.net/new/gear_knowledge/introduction_to_gears/types_of_gears. html Fernandes, P. (1996). Tooth bending fatigue failures in gears. Engineering Failure Analysis, 3(3), 219- 225. doi:10.1016/1350-6307(96)00008-8 https://www.sciencedirect.com/science/article/abs/pii/1350630796000088
- 20. References: Ronquillo, R. (n.d.). How Gears Work - Different Types of Gears, their Functions, Mechanisms and Applications. Retrieved July 16, 2020, from https://www.thomasnet.com/articles/machinery-tools-supplies/understanding- gears/ The Different Types of Gears. (n.d.). Retrieved July 10, 2020, from https://www.rexnord.com/blog/articles/types-of-gears Industrial Applications of Bevel Gears. (n.d.). Retrieved July 10, 2020, from https://bevelgearsindia.com/applications/ Nice, K. (2000, October 31). How Washing Machines Work. Retrieved July 17, 2020, from https://home.howstuffworks.com/washer6.htm
- 21. HOW GEARS ARE MADE? 02 Manufacturing of gears is step-by-step processes of turning raw materials to a function gear. It required several processing in operations sequential stages. It includes performing gear blanks, gear teeth production and finishing. Ref: https://nptel.ac.in/content/storage2/courses/112105127/pdf/LM-32.pdf
- 22. STEP 02 STEP 04STEP 03 STEP 05 Material selection Selected materials will be processed into a blank Performing Gear Blank Materials is cut a bigger size of desired dimensions Production of Gear Teeth Various of processes can be used to generate the actual dimension of the gear teeth. STEP 01 Finishing A proper finish is necessary in order to have a clean and longer gear lifespan. STEP 06 Quality Control A finished product must be inspected to decide if any needs for corrective actions Packaging and Delivery A final product is ready to deliver to the customer
- 24. casting Various casting processes can generate gear blanks includes sand casting, metal mould casting, die casting, centrifugal casting, etc. rolling Cold rolling used to produce straight and helical teeth of disc or rod type external steel gears. Powder metallurgy Powder metallurgy make a small high strength spur, bevel or spiral gears. It is less expensive in a large production quantities. Picture from: https://nptel.ac.in/content/storage2/courses/1 12105127/pdf/LM-32.pdf Gear MANUFACTURING PROCESS Picture from:: https://gearmotions.com/powdered-metal- gears/ Picture from: http://theinfoscience.blogspot.com/2016/01/what-is- casting.html Same area Blank diameter
- 25. GEAR MANUFACTURING PROCESS Extrusion Extrusion process usually produce high quality small metallic or non metallic external gears in large quantity. Plastic Moulding By injection moulding, plastic gears with or without metal core are manufactured. Moderately accurate and less noise gears and used under light loads. Blanking in Press tool Blanking from sheets is done to produce mass production of small and thin metallic gears. Usually, this kind of gears produced by blanking is used for clocks, watches etc. Picture from: http://tdimolding.com/plastic-injection- molded-gears/ Picture from: http://www.zndxzk.com.cn/down/2014/01_ znen/08-p0050-e121549.pdf Picture from: https://www.open.edu/openlearn/science-maths- technology/design- innovation/manufacturing/content-section-3.8 container billet die ram punch workpiece helical gear counterpunch die blank holder F
- 26. MACHINING: generatiNG PRINCIPLE Gear teeth produced by rotating the gear blank in contact with the rotating cutter. The cutter axis is parallel to the gear face. It will enter and exits the blanks, while moderately feed into the gear blanks to a desired depths. shaping hobbing Gear teeth produced by series of cuts using a hob (helical fluted cutting tools). Hob will axially fed the gear face and only can produce external gears teeth. Hob Pictures from: https://nptel.ac.in/content/storage2/courses/112105 127/pdf/LM-32.pdf
- 27. MACHINING: Forming principle gashing miling Use a multi-edge cutter that rotates into the gear blank. It mills to produce gear teeth one by one. broaching Use a multi toothed cutting tool called a broach. Usually used for producing internal gears. The gear blank is pushed into the broach to remove the internal of the blank. The depth of cut increases with each tooth. Picture from: https://www.engineeringenotes.com/manufacturing- science/material-removal-process/types-of-material-removal- process-multipoint-abrasive-and-finishing-manufacturing- science/52188 A process used on heavy duty milling machine to produce large coarse pitch on the blanks
- 28. Gear finishing Gear shaving A rotary gear shaving that removes small amounts of working surfaces of the gear teeth. Used to minimize the gear noise as it improves the surface of gear teeth. shaver Gear burnishing A machined gear teeth are polished by cold plastic flow to refine the gear surface. The gear is rolled under pressure with three hardened master gears of high accuracy and finish. Picture from: https://encyclopedia2.thefreedictionary.com/G ear-cutting+Machine https://www.semanticscholar.org/paper/Perfor mance-Improvement-of-Roller-Burnishing-A- Yadav- Ghatge/973dc675ac3f5e5ee2c41cbb3848310 shaver
- 29. Gear finishing Gear lapping Use a lapping tools to produce a high accuracy to gear teeth while applying a fine-grained abrasive between the workpiece and and a lapping plate. Gear grinding A critical step to get a high precision gear. It is mainly performed after the material undergoes the heat treatment process. A grinded teeth gear will produce low noise and evenly wear. wheel gear Picture from: https://nptel.ac.in/content/storage2/courses/112105127/pdf/LM-32.pdf https://www.amtechinternational.com/gear-lapping-grinding- services/https://www.amtechinternational.com/gear-lapping-grinding-services/
- 30. References: Gear Manufacturing Methods https://www.youtube.com/watch?v=B0XSsa79Y1w Gears - How its Made https://www.youtube.com/watch?v=XZgsV0AZJJ0&t=125s John P. Dugas (1986), The Process of Gear Shaving, National Broach & Machine, A Division of Lear Siegler, Inc https://www.geartechnology.com/articles/0186/The_Process_of_Gear_Shaving/ Module 7 - Screw threads and gear manufacturing methods https://nptel.ac.in/content/storage2/courses/112105127/pdf/LM-32.pdf Gear Grinding https://gearmotions.com/manufacturing/gear-grinding/
- 31. what materials are used in the making of gear ? 03 Gears basically are made of all sorts of materials as example steel, brass, bronze, cast iron, ductile iron, aluminum, powdered metals, and plastics.
- 32. BRONZE ALUMINIUM BRASSSTEEL CAST IRON Ref : https://my.rs-online.com/web/p/worm-wheel-gears/5216979/ Ref : http://www.bestagear.com/worm_gear/worm_gear_258.html Ref : https://www.indiamart.com/proddetail/aluminum-gear-13443429897.html Ref : https://www.okchem.com/showroom/cast-iron-gear-wheel.html Ref : https://www.directindustry.com/prod/maedler-gmbh/product-66929-1572034.html
- 33. Factors of material selection 01 02 03 cost DURABILITY strength
- 34. WHAT IS THE BEST MATERIAL FOR GEARS ? Due to the ease of manufacturing and the variety of alloys available, metal alloys are the most common material used for gears. Carbon or alloy steels are commonly used due to their high strength values. These steels are heat-treated in order to achieve the appropriate combination of toughness and tooth hardness. Cast iron is also a common gear material due to its good wearing properties, machinability, and the ease of producing complicated shapes via metal casting. Worm gears tend to use phosphor bronze because of the material’s wear resistance ability. Ref : https://www.machinedesign.com/learning-resources/engineering-essentials/article/21834512/gears-look-to-the-future-for- material
- 35. Conclusion 04 Best method in manufacturing gears and local companies in Malaysia manufactures gears
- 36. Best method in manufactures gears ● Broaching Faster method to remove the material using the multi-tooth cutting tools that called broach/gear blank Conventional method used to make internal gear and pop broaching used to make external broaching ● Milling To generate gears shape To produce large external/ internal gear the process called gashing What is gashing? Gashing is the rapid metal removal ● Heat-treatment To make hardness requirement ● Finishing To get a good and fine finishing GEAR FORM- CUTTING
- 37. Mt gear & engineering service sdn.bhd Supply and fabricates every kind of gears with a reasonable pricing to private corporate,SMI. And government agencies Specialized all kind of gears and general engineering service ● Gear grinding ● Gear cutting ● Repairing gear box & service gear box ● Undertake all type of Machinery Job Located at Sungai Pinang, Klang https://mtgear.com.my/
- 38. Hydena automation sdn bhd Established in March 2011 ● 9800 types of gears (always in stock) ● Provides low price because of standardize ● CAD drawing / Techinical detail available for all types of gears ● Their HQ at Japan have 75 years of experience in gear manufacturing Locate at Taman Perindustrian Puchong,Puchong http://www.hydena.com.my/
- 39. References: GEAR EXPLANATION- https://www.explainthatstuff.com/gears.html#:~:text=Similarly%2C%20in%20a%20car %2C%20gears,increasing%20speed%20and%20changing%20direction MATERIAL USE TO MAKE GEARS- https://www.ukessays.com/essays/engineering/materials-used-for-making-gears.php GEARS COMPANY- https://mtgear.com.my/ http://www.hydena.com.my/khk-gear/
- 40. LINKED IN: 1) MUHAMMAD ASYRAF BIN ISMANIZAN https://www.linkedin.com/in/muhammad-asyraf- ismanizan-82bb391b2/ 1) NURUL SYAZWANI BINTI SAHARI https://www.linkedin.com/in/syazwani-sahari-7087151a1 1) AMIER BAZLIE BIN JOHARI https://www.linkedin.com/in/amier-bazlie-ba6aa51b2/ 1) MOHAMAD SYAFIQ SALMAN BIN AZMAN https://www.linkedin.com/in/syafiq-salman-319b401b2/ YOUTUBE: https://youtu.be/QhnBznRRxiw SLIDESHARE:
- 41. CREDITS: This presentation template was created by Slidesgo, including icons by Flaticon, infographics & images by Freepik and illustrations by Stories THANKS!