ABSTRACT

The Project is based on attaching an additional VERTICAL MILLING ATTACHMENT to the HORIZONTAL BORING MACHINE. The objective of project is to reduce the time required to setting of the job this type of work is fatigue to the operator. Another objective is to produce jobs having more accuracy. All these results are accompanied by accurate design and

COMPANY PROFILE

COMPANY INFORMATION

CHAPTER 1
COMPANY INFORMATION
NAME: GEAR TORQUE TRANSMISSIONS ADDRESS: PLOT NO.W-48, Additional M.I.D.C., Satara, Maharashtra, (INDIA)

PRESENT PRACTICES & PROBLEMS

1. For machining the two mutually perpendicular face they machine 1st face & after that they rotate the job & machine 2nd face 2. For heavy jobs it becomes fatigue to rotate the job 3. It is also time consuming for setting & clamping the job SUGGESTIONS ON PROBLEM 1. Vertical Milling Attachment driven by same drive 2. Vertical Milling Attachment driven by same drive with gearing attachment 3. Vertical Milling Attachment driven by same drive with clutch system 4. Vertical Milling Attachment with independent driven drive

CHAPTER 2 LITERATURE REVIEW

To complete our project design we refer following Design Data Books & Reference Books.

1. PSG design data book:

We use PSG design data book for the design of gear. We refer chapter bevel gear & according to the formulae we complete our design.

2. CMTI design data hand book:

We refer material specification of gear & shaft, various stresses of material & also design of gear from the CMTI hand book.

3. MACHINE DESIGN by V.B. BHANDARI:

For the calculation of forces acting on the gear & shaft we refer reference book of machine design. We refer chapter bevel gear for gear design & force calculations.

4. MACHINE DESIGN by R.S. KHURMI:

For the calculations of the shafts, keys & also for the design of gear we use this book. We refer chapter design of shaft for shaft & key design.

5.IS STANDARD FOR SELECTION OF BEARING

CHAPTER 3. DESIGN
SELECTION OF MOTOR Required RPM: 500 Motor Specification: 3Phase Induction Motor RPM: 1440 Torque: We selected the available motor from company.

DESIGN OF BEVEL GEAR

Abbreviations: m= Module = Pitch Angle i= Gear Ratio b= Face Width mt =Transverse Module mn = Normal Module Zp=No. of Teeth on Pinion Zg=No of Teeth on Gear R1= Cone Distance dp= Reference Diameter For Pinion dg= Reference Diameter For Gear dpt= Tip Diameter Of Pinion dpg= Tip Diameter Of Gear Zcw= No of Teeth Crown Wheel Zu = Minimum No of Teeth on Pinion to Avoid the Undercutting m= Helix Angle = Pressure Angle ap= Addendum Angle For Pinion ag = Addendum Angle For Gear

c = Clearance ap= Tip Angle For Pinion ag= Tip Angle For Gear rp= Root Angle For Pinion rg= Root Angle For Gear ha= Tooth Height hd= Tooth Height

DESIGN:
By considering required speed We assume, m=3, Zp=24, Zg=72 i=Zp/Zg =20/60 =1/3 i =1:3 1. for , Tan =i Therefore, =tan-1 (i) =tan-1(1/3) =18.430 2. for mt, mt=mm+

=3+ mt =3.1mm 3. for mm mm= mtX cosm =3.12Xcos0 .......... (since, m=0)

=3.1mm 4. For cone distance R R=0.5Xmt =0.5X3.12X =117.636mm Zp2+Zg2) 242 +722)

5. Reference diameter, dp=mt X Zp =3.12X 24 =74.4mm dg=mt X Zg =3.12 X 72 =223.2mm 6. Tip diameter dpt= mt X (Zp+ 2cosp) = 3.12 X (24+2cos18.43) = 80.28mm dgt= mt X (Zg+ 2cosg) = 3.1 X (72+2cos71.57) =225.160mm 7. No of teeth on crown wheel Zcw=2R/mt = =75.89mm 8. Minimum no of teeth on pinion to avoid undercutting

Zu=

= =16.22 9. Addendum angle tan ap= tan ag =

.................... (=200)

ap = ag = tan-1 ap = ag =1.50 10. dedendum angle tan dp= tan dg =

dp = dg = tan-1 dp = dg =1.810 11. tip angle ap = + ap =18.43 + 1.5 =19.930 ag = + ap = 71.57 + 1.5 = 73.070 12. Root angle rp = dp = 18.43 1.81 = 16.620 rg = dg = 71.57 1.81

= 69.760 13. Tooth height, h h= ha + hd ha = mt =3.1mm hd = 1.1236 mt =3.50mm ................. (Reinecker)

GEAR TOOTH PROFILE

FORCES ACTING ON GEAR TOOTH

Abbreviations:
b = P= Np = Ng = rm = Ps = Pt = Mt = Pa = Pr = Ultimate tensile stress Power in kW Speed of pinion in rpm Speed of gear in rpm Radius of pinion at midpoint of face-width separating force between two meshing teeth tangential or useful component torque transmitted by gear axial component on pinion radial component on pinion

1. ultimate tensile stress b =63kgf/mm2 = 63 X 9.81 = 618.03 N/mm2 = 620 N/mm2 2. power to be transmitted by the motor 1.5kW @ 1440 rpm 3. for radius of the pinion at midpoint of face width rm =

= =32.45mm

4. Tangential or useful component Pt= But, mt= Pt X rm

Therefore mt= = 9947.18 N-mm Pt=

= = 306.53N 5. separating force between two meshing teeth Ps=Pt tan =306.53 tan20 =111.57 N 6. axial component on pinion Pa=Pssin =111.57 X sin18.43 =35.27 N 7. radial component on pinion Pr=Ps cos = 111.57 cos18.43 = 105.84 N

8. axial component on gear Pa= Pttan tan =376 X tan20 Xsin18.43 =43.26 N

9. radial component on gear Pr=Pt tan sin = 306.63Xtan20Xsin18.43 =35.27N

 Strength of Bevel Gear:

Abbreviations: Wt=strength of wear gear
o

=shear start

yp= form factor for pinion yg=form factor for gear Zep=equivalent teeth of pinion Zeg=equivalent teeth of gear Cv=velocity factor

1.

Wt=( o*Cv)*b**n*y* o= 620/1.5 =413.34 N/mm2

`Form factor for pinion

Yp=0.154Zep=Zpsec =20*sec18.43 =21.08 Therefore, Yp=0.154=0.1107

Vm=

= =4.70 m/s Therefore, Cv=

= =1.78 Wt=413.34 X 1.78 X 30 X X 3 X 0.1107 X =17155.75117 N 2. form factor for gear yg=0.154-( )

Zeg=Zg sec =60sec18.43 =63.24

yg=0.154=0.139

Wt=413.34 X 1.78 X 30 X X 3 X 0.139 X =21539.35 N

 WEAR STRENGTH: Sw=wear strength Q=

= =1.80

k=0.16(

)2

=0.0484 N/mm2 Wear strength Sw=

= =123.97 N Effective load Peff between two meshing teeth is given by

Peff=

= =264 N

DESIGN OF SHAFT

d= 0.5R = 0.5 X 117.63 = 58.82mm d1= 1.6 X d = 1.6 X 58.82 = 94.1088mm a= 0.2 X R = 0.2 X 117.63 = 23.53mm c= 0.3 X d = 0.3 X 58.82 = 17.64mm l= 1.1 X d = 1.1 X 58.812 = 64.70mm

TAPER BERINGS SELECTION SELECTION OF BEARINGS

STANDARD TABLE FOR BEARING

Selected bearings- SKF DESIGNATION 32208 & 32210

CHAPTER 4 ASSEMBLY AND PART DRAWINGS 1) PART DRAWINGS

GEAR DESIGN:

PINION DESIGN:

BASE PLATE:

INPUT SHAFT:

OUTPUT SHAFT:

VERTICAL BEARING FLANGE:

HORIZONTAL CASING:

45O ATTACHMENT

VERTICAL CASING:

HORIZONTAL BEARING FLANGE:

ASSEMBLY DRAFTING

CHAPTER 5
CRITICAL PATH METHOD DIAGRAM

Activity
A B C D E F H G I J K L M N O P Q R S T U

Name of Activity
Project search Project finalization Documentation Design Analysis and force calculation Manufacturing of pinion Manufacturing of gear Manufacturing of input shaft Manufacturing of output shaft Manufacturing of bearings Manufacturing of flanges Manufacturing of horizontal casing Manufacturing of vertical casing Manufacturing of 450attachment Nut and bolts Manufacturing of support Motor selection Assembly Testing Painting Attachment

Immediate Predecessor
A B C D E F H G H,I J K K L,M L O P Q R S T

Duration(in days)
20 5 30 30 15 1 2 2 3 1 3 2 3 4 0 4 1 15 10 5 5

TOTOL DAYS= 161 days

Activity 1-2 2-3 3-4 4-5 5-6 6-7 6-8 7-9 8-9 9-10 10-11 11-12 11-13 12-14 13-14 14-15 15-16 16-17 17-18 18-19 19-20

Duration 20 05 7 30 15 1 2 2 3 1 3 2 3 1 4 4 1 15 10 5 5

Earliest time
Start Finish

Latest time
Start Finish

Total float 0 0 0 0 0 2 0 2 0 0 0 4 0 4 0 0 0 0 0 0 0

0 20 25 32 62 77 77 78 79 82 83 86 86 88 89 93 97 98 113 123 128

20 25 32 62 77 78 79 80 81 83 86 88 89 89 93 97 98 113 123 128 133

0 20 20 32 62 79 77 80 79 82 83 90 86 92 89 93 97 98 113 123 128

20 25 32 62 77 80 79 82 82 83 86 92 89 93 93 97 98 113 123 128 133

Critical path1-2-3-4-5-6-8-9-10-11-13-14-15-16-17-18-19-20 Total duration= 133 Days.

CHAPTER 6 BILL OF MATERIAL Sr. No.

1 2

Part name
SUPPORT BEVEL GEAR a) PINION b) GEAR HORIZONTAL CASING INPUT SHAFT OUTPUT SHAFT BEARING SUPPORT FLANGE a) INPUT SHAFT b) OUTPUT SHAFT TAPER BEARING a) INPUT SHAFT b) OUTPUT SHAFT 45 ROTATION ATTACHMENT BOLT a) M 12 b) M 16 NUT a) M 16

Material
MS EN 353 EN353 MS EN 36 EN 36 MS MS B.S. B.S. MS (HARDENED) EN 8 EN 8 EN 8

No off
1 1 1 1 1 1 1 1 1 1 1

Make/buy
Make Make Make Make Make Make Make Make Buy Buy Make

2 3 4 5

7 8

28 06 06

Buy Buy Buy

EN 353 Case Hardened Steel - 251570 MATERIAL COMPOSITION - 15Ni 2Cr 1Mo 15

CHAPTER 7
CONCLUSION
After completion of design of VERTICAL MILLING ATTACHMENT for horizontal boring machine, a final design is submitted to the company. The company is satisfied with our work and also we had a great experience working with the company. The cost of purchasing of new machine for milling is very high. By using our attachment the cost is reduces. Also at one time we not only bore but also mill the same job as per requirement.

CHAPTER 8
REFERANCES 1. DESIGN DATA BOOK (PSG) 2. MACHINE DESIGH BY V.B. BHANDARI 3. CMTI 4. MACHINE DESIGN BY KHURMI GUPTA 5. ISO STANDARD 6. MACHINE TOOL DESIGN BY N.K. MEHTA