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Modeling And Core Cavity Preparation Of Side

Engine Cover Of A Gear Box Casing Using Pro/E
Software
Conference Paper December 2010

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Shivraj Yeole
VNR Vignana Jyothi Institute of Engineering
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11. MODELING AND CORE CAVITY PREPARATION OF SIDE ENGINE COVER OF A

GEAR BOX CASING USING PRO/E SOFTWARE
1

Y. Shivraj Narayan , K. Karumanchi

1

Associate Professor, Research Scholar

Department of Mechanical Engineering

VNR Vignana Jyothi Institute of Engineering & Technology, Hyderabad 500 090
Abstract:
Gear box casing is an essential component in engine of an Automobile. Function of Gear box casing is to
protect and guide the Gear transmission. In these casing the gear transmission is to regulate the speed from
engine to driving wheel. Gear box casing is an assembly of three parts namely main housing, side engine
cover and side differential cover. This paper deals with modeling of the side engine cover of gear box
casing for a mini truck and preparation of core cavity for the same by using Pro-Engineer Wildfire 2.0
software. Pro-Engineer is a 3D modeling software for modeling & manufacturing of complicated shapes
and parts. Advanced and sophisticated features of Pro-Engineer software have enabled us to model the
minute technicalities of the side engine cover with great ease. Also various steps were followed for the
preparation of core cavity of side engine cover in the manufacturing module of Pro-Engineer soft ware.
Thus the 3D model of the side engine cover of gear box casing of a mini truck and the core cavity required
for manufacturing it is obtained using Pro-Engineer software.
Keywords: Core cavity, Gear box casing, Pro-E software

1.

INTRODUCTION:

Gear box casing is an assembly of three parts. These are main housing, side
engine cover and side differential cover. The main objective of this work is to model the
side engine cover of gear box casing using Pro/Engineer wild fire2.0 software and also to
prepare core cavity for the same. Side engine cover of Gear box casing taken up for
modeling is used in mini trucks - Model: TEJA (Goods Auto). The design of side engine
cover of gear box casing of TEJA model is provided by M/S M.L.R MOTORS LTD
(Auto Division), Hyderabad. Gears are used as independent units to reduce or increase the
input speed. The unit is enclosed in rigid closed housing s (called casing) which supports
the shafts, hold lubricant inside casing, and protect the gears from dust and moisture. Also
the housing provides necessary cooling surfaces to dissipate the heat generated during
operation. When the unit is used to get only one reduced output speed for a given input
speed then it is called a SPEED REDUCER, while for one input speed more than one
output speeds are obtained, then the unit is called a GEAR BOX. Gear box is widely used
for reduction of speed in automobiles. The function of these SIDE ENGINE COVER
(part of gear box casing) is to protect and guide the gears used in power transmission. In
this casing, power transmission is done by regulating the speed of driving wheels
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through crank shaft to rear axle. The material used in making the Gear box casing is
Aluminum alloy Grade LM25. Using this alloy, casting for gear box casing is made which
is used in most of the automobiles such as motor bikes, passenger cars and passenger
autos etc. The engine capacity of the Mini truck is 7.5BHP/5.51KW; Speed of the engine
is 3600R.P.M. Aluminum alloy Grade LM25 is used due to its following characteristics:

1)

Good thermal conductivity (Heat conducting capacity)

2)

Excellent Fluidity,

3)

Good resistant to corrosion,

4)

Suitable for intricate castings,

5)

Good weld ability,

6)

Electrical conductivity.

Aluminum alloy Grade: LM 25

Compositio

Cu

Mg

S)

Fe

Ni

Mn

Zn

Pb

Sn

Tn

0.2

0.2-

6.5-

0.5

0.1

0.3

0.1

0.1

0.05

0.2

0.6

7.5

max

max

max

max

max

max

max

max

Table 1. Material & its chemical composition

2.

MODELING OF SIDE ENGINE COVER:

Pro-E Wildfire 2.0 software is used for the modeling of side engine cover of

minitruck, due to its ease of modeling the features, speed, accuracy & precision and
provision of modeling, assembling and preparing a core cavity. Part modeling is used to
create parts from section sketches, modify parts, and adding features to the parts. There
are many kinds of features that can be created on a part. There are solid features and
surface features, and features for specified applications. Part modeling refers to the
creation of solid features and removes material. The most basic way to add the materials
is through protrusion and to remove the material is through cut. In part modeling there are
different options to create parts.

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Various tools are used to create the part model of the side engine cover. They are sketch,
extrude, shell, revolve, sweep, blend, surface modeling.
EXTRUDE: The extrude option sweeps a sketched section along a straight trajectory. The
user draws the section in the sketcher environment and then provides an extrude depth. The
section is protruded the depth entered by the user.

SHELL: The shell option produce the hollow section in the extruded entity to provide
thickness around the selected trajectory and variable thickness can be produce.
REVOLVE: The revolve option sweeps a section around a center line. The user sketches a
profile of the revolved feature and a centerline from which to revolve. The user then inputs
the degrees of revolutions.

SWEEP: The sweep option protrudes a section along a user-sketched trajectory. The user
sketches both the trajectory and the section.

BLEND: The blend option joins two or more sketched sections. The trajectory may be
straight or revolved.

ADVANCED: Common modeling options under the advance menu include variable section
sweep, sweep blend and helical sweep.

SURFACE MODELLING: PRO/E surface creation tools are useful for modeling parts
with complex curves and surfaces

Figures 1 to 8 shows the various stages of modeling the side engine cover of a minitruck.

Fig. 1. First Sketch of the side engine cover

Fig. 2. First Extrude of the side ngine cover

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Fig. 3. Second Sketch of the side engine cover Fig. 4 Second Extrude of the side engine cover

Fig. 5. Shell of the side engine cover

Fig. 6. Sketching of side radius

Fig. 7. Bottom view of the side engine cover

Fig. 8. Top view of the side engine cover

3. ASSEMBLY & MOLD PREPARATION (Extraction):

3.1 Gear casing Die, Core & Cavity Design with Pro/Engineer:

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Mold design is an optional module for Pro/Engineer that provides the tools to simulate
the mold design process with in Pro/Engineer. This module lets you create, modify, and
analyze the mold components and assemblies, and quickly update them to the changes in
the design model. Casting provides tools to design die assemblies and components and
prepare castings for manufacturing. Assembly & Mold preparation for the side cover of
engine is obtained through the following steps:
Design Part Creation and Modification
Create models in Pro/Engineer including features requiring Pro/Surface
Import and repair geometry if necessary
Analyze if a design part is moldable, using Draft Check and thickness check
capabilities
Automatically create parting lines and detect undercuts using Silhouette curve
functionality
Fix problem areas by creating draft, rounds, and other features as needed.

Cavity Creation
Assemble and orient design model dynamically while checking draft and projected
area
Apply a shrinkage that corresponds to design part material, geometry, and molding
conditions
Automatically create the work piece stock from which core, cavity, and inserts will
be split
Create parting geometry including sliders, inserts, parting lines & automatic parting
surfaces
Automatically split the work piece to create cores, cavity, and inserts as solid
models
For casting, create and assemble sand cores
Mold Layout Creation
Create top level mold assembly
Placement and patterning of mold cavities to allow multi-cavity molding
Online selection and automatic assembly of standard mold bases
Modification of mold base plates to allow for assembly of mold cavity
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Online selection and automatic assembly of ejector pins and other mold catalog items

Automated creation of runners

Automated creation of waterlines, including 3-D waterlines interference checks
Define and simulate mold opening and check for interference between mold
components
Drawing Creation
Create complete pro duction drawings including dimensions, tolerances, automatic
bill of materials (BOMs) w ith or without balloon notes
Use of drawing templates
Figure 9 shows the flow c hart for mold design in Pro/E software.

Fig. 9. Flowchart for Mold Design in ProEngineer Software

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Fig. 10. Model (assembly component at default location interface)

Fig. 11. Final core

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Fig. 12.Final cavity

Fig. 13. Core cavities, inserts, riser blocks assembly location

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Fig. 14. 3D Model of Minitruck (TEJA) showing Side Engine Cover

4. CONCLUSIONS:
Side engine cover of a gear box, used in mini truck (Model: TEJA), has been successfully
modeled from the design provided by M/S M.L.R MOTORS LTD. Hyderabad using ProEngineer wildfire 2.0 software. Also core cavity required for manufacturing of side
engine cover of a gear box casing is prepared in the manufacturing module of ProEngineer software. A prototype model of the side engine cover of the gear box has been
successfully manufactured and assembled in the minitruck.
5.REFERENCES:
1) Yehoram Uziel, Prototype Tooling in Blocks and Cylinder Heads Yields a Complete
New Engine Design, International Congress & Exposition, Detroit, SAE International, 1998

2) T. V. Sundararajamoorthy, Gear Box - Machine Design, Anuradha Agencies, 2006

Edition, pp. 20.1-20.28.

3) R. S. Khurmi & G. K. Gupta, Bearing - Machine design, S. Chand Publications,

2008 Edition, pp-962

4) R.G.W. PAY, Injection Mould Design, East West Press Pvt. Ltd., 2000 Edition, pp2.
5) Design Data Handbook: Aluminum Properties, P.S.G.College of Technology,
Kalaikathir achchagam, 2007 Edition.
6) Pro/e modeling &Pro mold: Win wills library, Pro/E Help
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