FABRICATION OF

SPUR GEAR
Course ME 3118

Supervised by Submitted By
Md.Golam Kader Md Rezowan Kabir [1205016]
Professor, Md Hasanuzzaman [1205017]
Md Rasedul Islam Md Abul Kashem Hemel [1205018]
Lecturer, Md Ashik Mahmud [1205019]
Department of Mechanical Saikat Biswas [1205020]
Engineering, KUET

Department of Mechanical Engineering

Khulna University of Engineering & Technology
Khulna-9203, Bangladesh
 TABLE OF CONTENTS
Page

Acknowledgement ------------------------------------------------ i
Abstract -------------------------------------------------------------- ii
List of figures ------------------------------------------------------- iii
List of tables -------------------------------------------------------- iv
Nomenclatures ------------------------------------------------------ v
Chapter 1: Introduction
1.1 Objectives--------------------------------------------------- 01
1.2 Introduction-------------------------------------------------- 02
1.3 Types of Gear ------------------------------------------------03
1.4 Spur Gear-----------------------------------------------------04
1.5 Application ----------------------------------------------------05
Chapter 2: Gear Terminology
2.1 Gear Terminology------------------------------------------06
2.2 problem-------------------------------------------------------09
2.3 Solution -------------------------------------------------------10
2.3 solidworks design--------------------------------------------13
2.4 Keyshot Rendering -----------------------------------------14
 Chapter 3: Construction
page

3.1 Materials-------------------------------------------------- 15
3.2 why we choose Cast iron -------------------------------16
3.3 Manufacturing process of spur gear ------------------ 16
3.4 Reason for choosing Milling process-------------------17
3.5 Milling Process--------------------------------------------17
3.6 Methodology ----------------------------------------------18
Chapter 4: Conclusion
4.1 Result & Discussion --------------------------------------20
4.2 Final project ------------------------------------------------20
4.3 Conclusion --------------------------------------------------21
Chapter 5: References
5.1 References --------------------------------------------------22
 ACKNOWLEDGEMENT

Thanks to almighty God for enabling and helping the authors to carry out
this project work.
The authors would like express sincere gratitude to their supervisors
Md.Golam Kader, Professor and Md. Rasedul Islam, Lecturer,
Department of Mechanical Engineering, KUET, for their consultation and
discussion which were essential to carry out this work. They were always
accessible and willing to help them to carry out this project.
Authors want to express their sincere gratitude to Prof. Dr. Nawsher Ali
Moral, Head, Department of Mechanical Engineering, KUET, who gave
them permission to work in machine shop, welding shop and heat engine
laboratory.
Also thanks to all the lab assistants who helped the authors in order to
achieve the project goal.

“Authors”

i
 ABSTRACT

A gear is a rotating machine part having cut teeth, which mesh with
another toothed part to transmit torque, in most cases with teeth on the
one gear being of identical shape, and often also with that shape on the
other gear. Gear is used for Changing the direction through which power
is transmitted (i.e. parallel, right angles, rotating, linear etc.), Changing
the amount of force or torque, Changing RPM.
Spur Gear is a very important type of gear. Spur gears are the most
commonly used gear type. They are characterized by teeth which are
perpendicular to the face of the gear. Teeth are parallel to axis of rotation.
In this project work a spur gear was made based on a mathematical
problem from “problem book of FAIRES VIRGIL MORING, “DESIGN
OF MACHINE ELEMENTS”, 4th edition, The Macmillan Company, New
York/Collier-Macmillan Limited, London”. The gear was made by cast
iron. Because of its strength & availability.
In this project work, finally a spur gear was completed and every updates
were given regularly.

ii
 List of Figures
Figure Title page
Figure 1.1 Gears 2
Figure 1.2 Gear meshing 3
Figure 1.3 Spur gear 4
Figure 2.1 Spur gear terminology-1 6
Figure 2.2 Spur gear terminology-2 7
Figure 2.3 Pressure angle of Spur gear 8
Figure 2.4 Dimensions of Spur gear 13
Figure 2.5 Rendering images 14
Figure 3.1 Milling process 18
Figure 3.2 Milling machine 19
Figure4.1 Manufactured Spur Gear 20

iii
 List of tables
Table Title page
Table 2.1 calculation for pitch diameter 11

iv
 Nomenclature

Symbol Description

PD------------------------------------------- Diametral pitch

Hp------------------------------------------- Horse power
kf -------------------------------------strength reduction factor
Ft----------------------------------------- Transmitted load
FD--------------------------------------- Dynamic load
Fs------------------------------------------ Safe load
mw ------------------------------------ Velocity ratio
vm ------------------------------------ pitch line speed
b---------------------------------------- Face width
Np------------------------------------------------ Pinion teeth
Ng------------------------------------------------ Gear teeth
Nsf ---------------------------------------------- Service factor

v
Chapter 1

 Objectives
 Introduction
 Types of Gear
1.1 Objectives
 To Study about gear.
 To Study about the classification of gear.
 To Study about spur gear.
 Fabrication of spur gear.
 To Study of advantages and disadvantages of
spur gear.

Page 1
1.2 Introduction:
A gear is a rotating machine part having cut teeth, which mesh with
another toothed part to transmit torque, in most cases with teeth on the
one gear being of identical shape, and often also with that shape on the
other gear.
Two or more gears working in a sequence are called a gear train or, in
many cases, a transmission; such Gear arrangements can produce a
mechanical advantage through a gear ratio and thus may be considered a
simple machine.

Figure 1.1 Gears

Page 2
Gears are used to Control Power Transmission in These Ways
1. Changing the direction through which power is transmitted (i.e.
parallel, right angles, rotating, linear etc.)
2. Changing the amount of force or torque
3. Changing RPM
When two gears mesh, and one gear is bigger than the other (even though
the size of the teeth must match), a mechanical advantage is produced,
with the rotational speeds and the torques of the two gears differing in an
inverse relationship.

Figure 1.2 Gear meshing

1.3 Types of Gear:

According to the position of axes of the shafts.
 Parallel
1.Spur Gear
2.Helical Gear

Page 3
 3. Rack and Pinion
 Intersecting
1. Bevel Gear
 Non-intersecting and Non-parallel
1.worm and worm gears

1.4 Spur Gear:

Spur gears are the most commonly used gear type. They are characterized
by teeth which are perpendicular to the face of the gear. Spur gears are by
far the most commonly available, and are generally the least expensive.
 Teeth is parallel to axis of rotation
 Transmit power from one shaft to another parallel shaft
 least expensive

Figure 1.3 Spur gear

Page 4
1.5 Applications of Spur Gear:
 Metal cutting machines
 Power plants
 Marine engines
 Mechanical clocks and watches
 Fuel pumps
 Washing Machines
 Gear motors and gear pumps
 Rack and pinion mechanisms
 Material handling equipments
 Automobile gear boxes
 Steel mills
 Rolling mills

Page 5
Chapter 2

 Gear Terminology
 Problem
 Solution
 Dimensions
 Solidworks Design and keyshot
Rendering
2.1 Gear Terminology :
Pitch surface : The surface of the imaginary rolling cylinder (cone,
etc.) that the toothed gear may be considered to replace.

Pitch circle: A right section of the pitch surface.

Root (or dedendum) circle: The circle bounding the spaces between
the teeth, in a right section of the gear.

Addendum: The radial distance between the pitch circle and the
addendum circle.

Dedendum: The radial distance between the pitch circle and the root
circle.

Figure 2.1 Spur Gear Terminology [1]

Page 6
Clearance: The difference between the dedendum of one gear and the
addendum of the mating gear.

Face of a tooth: That part of the tooth surface lying outside the pitch
surface.

Flank of a tooth: The part of the tooth surface lying inside the pitch
surface.

Circular thickness (tooth thickness) : The thickness of the tooth

measured on the pitch circle. It is the length of an arc and not the length
of a straight line.

Figure 2.2 Spur Gear Terminology [2]

Tooth space: The distance between adjacent teeth measured on the

pitch circle.

Page 7
Backlash: The difference between the circle thickness of one gear and
the tooth space of the mating gear.

Module m : Pitch diameter divided by number of teeth. The pitch

diameter is usually specified in inches or millimeters; in the former case
the module is the inverse of diametral pitch.

Fillet : The small radius that connects the profile of a tooth to the root
circle.
Pinion: The smaller of any pair of mating gears. The larger of the pair is
called simply the gear.

Velocity ratio: The ratio of the number of revolutions of the driving (or
input) gear to the number of revolutions of the driven (or output) gear, in
a unit of time.

Pressure angle: Pressure angle in relation to gear teeth, also known as

the angle of obliquity, is the angle between the tooth face and the gear
wheel tangent. It is more precisely the angle at a pitch point between the
line of pressure (which is normal to the tooth surface) and the plane
tangent to the pitch surface.

Figure 2.3 Pressure Angle of spur gear

Page 8
2.2 Problem :
It is desired to transmit 30 hp at 1800 rpm of the pinion; intermittent
service; with light shock (§13.18); preferably not less than 20, 20o -full-
depth teeth on the pinion; strength reduction factor Kf = 1.25 should be
conservative; mw =1.5 Decisions must be made concerning the material
and quality of cutting the teeth. Since the design is for strength only, it
will be convenient to express Ft , Fd , vm ,face width b in terms of pitch Pd
and arrange an equation containing s and Pd convenient for iteration.
Weak material results in a relatively large pinion with high peripheral
speed. A very strong material may be unnecessarily expensive. On a
production bases carefully cut teeth should have a reasonable cost.
Specify material, accuracy of cutting, pitch, face width, and tooth
numbers.

Page 9
2.3 Solution:
Np 20
Dp= =
Pd Pd
20
𝜋Dpnp 𝜋( ) 9424.78
Pd
Vm= = *1800=
12 12 Pd
33000ℎ𝑝
Ft= = 105.04Pd
Vm

120hp>20hp
use Buckingham’s equation

.05Vm (cb+Ft)
Fd= Ft+
.05Vm+√(cb+Ft)

Assume a material of steel, as rolled AISI 1050,

Su= 102 ksi
For carefully cut teeth, Fig. AF 20, e .0001 in (min.)
Table AT 25, steel on steel, 200 F.D.
C  1660
assume
8.5
b=
Pd

Page 10
 9424.78 8.5
.05( )[1660( +105.04Pd)]
Pd Pd
Fd= 105.04Pd+ 9424.78 8.5
.05( )+√[(1660 +105.04Pd)]
Pd Pd

𝑠𝑏𝑦
Fs=
PdKf

Weak pinion Table AT 24,Np =20

, Y =.0522 (Load near middle, 200 F.D.)
S=0.5Su= 0.5*102=51ksi=51000 psi

8.5
(51000)( )∗0.522) 2262
Pd
Fs= =
1.25Pd Pd

Fs= Fd Nsf
(§13.18), light shock, Nsf 1.25
Table 2.1
Pd Fd Fs Nsf(≤ 1.25)

7 2281.57 3694.48 1.62

8 2235.645 2828.5875 1.2652

Pd =8
8.5
b=
Pd

Page 11
 Ng
Np= 20 , = mw
Np

Ng=20*1.2=24
b=1.0625
Np=20
Ng=24

So the pitch diameter of the gear Pd = 8

Face width b =1.0625 inch
Number of teeth = 24

Page 12
2.4 Drawing & Dimensions

Figure 2.4 Drawing & dimensions

Page 13
2.5 Rendering Image

Figure 2.5: Rendering images

Page 14
Chapter 3

 Materials
 Why we choose cast iron
 Manufacturing process
 Procedure
 Final project
3.1 Materials:

1. Steel
2. Cast Iron
3. Stainless Steel
4. Aluminum
5. Bronze
6. Nylon
7. Non-metallic phenolic

Page 15
 3.2Why we choose Cast Iron?
• High tensile strength to prevent failure against
static loads.
• High endurance strength to withstand dynamic
loads.
• Low coefficient of friction.
• Good manufacturability.
• Low cost
• High availability

3.3 MANUFACTURING PROCESS OF SPUR GEAR:

1. Casting
2. Milling
3. Broaching
4. Gear hobbing
5. Gear forming

Page 16
3.4 Reason for choosing Milling process:
1. It is Compatible with All Materials
2. Flexible Use
3. Short Lead Times
4. Better accuracy

3.5 Milling process:

This is one of the initial and best known and metal removal
process for making gears. This method requires the usage of a
milling machine. It is also to be noted that this method can
produce nearly all types of gears. The method involves the use of
a form cutter, which is passed through the gear blank to create the
tooth gap. This method is right now used only for the manufacture
of gears requiring very less dimensional accuracy. To put it
correctly this method is currently outdated.

Page 17
 Figure 3.1 Milling Process

3.6 Methodology:
The gear blank is mounted on a mandrel which is supported between the
center of the dividing head and one more center at the other end, as shown
in fig. At a time one tooth space is cut by the milling cutter, and a dividing
head is used to index the job to the next required tooth space. The cutter
is chosen according to the module (or DP) and number of teeth of the gear
to the cut. This cutter is mounted on the milling arbor. Before the gear can
be cut, it is necessary to have the cutter centered accurately relative to the
gear holding mandrel. One way is to adjust the machine table vertically
and horizontally until one corner of the cutter just touches the mandrel on
one side. Both the dials (of the table and the knee) are then set to zero.
The table is then adjusted for the cutter to just touch on the other side of
the mandrel with vertical dial showing zero. The reading of the horizontal

Page 18
feed screw is read. This reading divided by two gives the central position
of the mandrel relative to the cutter. When the table is set centrally in this

Figure 3.2 Milling Machine

manner it should be locked in that position. The table is then fed vertically
so that the blank just touches the cutter. The vertical dial is then set to
zero. This is required to give the depth of cut on the job.

With these settings the machine can be started and traversed along the axis
of the job to cut the tooth over the whole width of the gear. Depth is
increased slowly until it reaches the full depth of the tooth. With the depth
setting the backlash of the gear can be controlled suitably. After one tooth
space is cut, the blank is indexed through 1/z revolution by means of the
dividing head, and the process is repeated until all the teeth are cut.

Page 19
Chapter 4

 Result and Discussion

 Conclusion
4.0 CONCLUSION:

4.1 Result & Discussion:

By analyzing the selected problem, all steps are completed to manufacture
a spur gear. All dimensions are taken based on the problem. After
completing several machining process expected spur gear is found. For
light shock the value of Nsf should be 1.25< Nsf <1.5. The value of Nsf of
the designed gear is within the range .So the design will be safe from the
failure

4.2 Final Project

Fig4.1: Manufactured Spur Gear

Page 20
4.2 Conclusion:
By performing this project we had learnt the design of spur gear, analysis
of a spur gear terminology, solving related problem, calculating safety
factor of it & the safe arrangement of it. In future it will be helpful for us
to choose the right gear among various types gear.

Page 21
Reference
5.1References
[1] FAIRES VIRGIL MORING, “DESIGN OF
MACHINE ELEMENTS”, 4th edition, The Macmillan
Company, New York/Collier-Macmillan Limited,
London
[2] Jain R.K., “ Production Technology”, 16th edition, 2-
B, Nath Market, Nai Sarak, Delhi-110006
[3]http://www.brighthubengineering.com/manufacturin
g-technology/7118-gear-manufacturing-methods

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