1.

PROJECT PLANING
Before starting every project its planning is to be done. Planning is very important task and should be taken with great care, as the efficiency of the whole project largely depends upon its planning while planning a project each and every details should be worked out in anticipation and should carefully is considered with all the relating provisions in advance. Project planning consists of the following steps.

PROJECT CAPACITY
The capacity of the project must be decided considering the amount of money which can be invested and availability of material and machines.

DRAWINGS
Drawing been decided for the project to be manufacture. Its detailed drawing specification for raw material and finished products should be decided carefully along with the specification of the machines required for their manufacture.

MATERIAL EQUIPMENT
The list of materials required for manufacture is prepared from the drawings. The list of is known as BILL OF MATERIALS. This passes to the store keeper and the required materials taken from the store under permission of store keeper operation, the necessity of operation, the person to do the job, machine to be used to do the job are considered while planning the operation. After considering tea above questions a best method is developed and the best method is applied to the operation.

MACHINE LODING
While planning proper care should be taken to find the machining time for each operation as correct as possible. So that the arrangement for full utilization of machine can be made machine loading programmed is also known.

PURCHASE CONSIDERATION
It is different to manufacture all the component needed for the equipment in the workshop itself. The decision about a particular item whether to purchase or to manufacture is taken by planning after making through study of relative merits demerits.

EQUIPMENT CONSIDERATION
Result obtained from PROCESS PLANNING and MACHINE LODING helps in calculating the equipment requirement specification of the equipment should be laid down by considering the drawing. Drawing will also help in deciding and necessary requirement of tools, accessories.

COST CALCULATION
The cost of the project can be calculated by adding following. 1. Material Cost 2. Machining Cost 3. Overhead Expenses.

COMPARION
The various items in the finished project are compared to the standards for the further correction.

REPORT
At the end of the project work report is prepared for future references. The report consists of all the items done the project work.

2. INTRODUCTION OF GEAR BOX Gears are a means of power transmission and changing the rate of rotation of a machinery shaft. They can also change the direction of the axis of rotation and can change rotary motion to linear motion. Unfortunately, mechanical engineers sometimes shy away from the use of gears and rely on the advent of electronic controls and the availability of toothed belts, since robust gears for high-speed and/or high-power machinery are often very complex to design. However, for dedicated, high-speed machinery such as an automobile transmission, gears are the optimal medium for low energy loss, high accuracy and low play. The intricacies of a gears terrain offer challenges to even the most experienced quality control engineer. As gear specifications tighten, tolerances often drop to the submicron realm. Hobbing, shaving, and grinding machines that offer already high accuracies can lag behind the quality demands of their finished product. Culprits include uneven or incorrectly mounted cutting tools, the results of which manifest themselves in profile errors, flankline deviation, variation in tooth thickness, pitch error, and deviations in flank shape. A gear that deviates from the ideal will make itself heard and seen. Substandard gears are noisy during operation, wear down quickly, and fail prematurely. Here we present a broad and comprehensive report on Gear Metrology explaining Gear classification and terminology, Metrological aspects of Gears (Cylindrical parallel axis involute gears), Standards of Gear measurements, Measurement techniques and Measuring equipment. This report is intended to formalize the procedures used for measuring lead, profile and pitch errors in involute gears using dedicated gear measuring machines and CMMs with gear measurement software. It should be used when gear tolerances are specified in accordance with existing

gear standards (e.g. ISO 1328, AGMA 390.2, BS 436) and assumes that basic background knowledge of involute geometry and the measurement techniques are familiar to the reader. ISO Technical Report TR 10064-1 1992: 1 background information is recommended for more detailed study.

3.GEAR CLASSIFICATION Gears are of several categories, and can be combined in a multitude of ways, some of which are illustrated in the following figures: SPUR GEAR: Spur gears are the most common type of gear having radial teeth parallel to the axle. They have straight teeth, and are mounted on parallel shafts. Sometimes, many spur gears are used at once to create very large gear reductions. Each time a gear tooth engages a tooth on the other gear, the teeth collide, and this impact makes a noise. It also increases the stress on the gear teeth HELICAL GEAR: A gear wheel meshed with another so that their shafts are at an angle less than 180 degrees. The teeth on helical gears are cut at an angle to the face of the gear. When two teeth on a helical gear system engage, the contact starts at one end of the tooth and gradually spreads as the gears rotate, until the two teeth are in full engagement. This gradual engagement makes helical gears operate much more smoothly and quietly than spur gears. For this reason, helical gears are used in almost all car transmissions. Because of the angle of the teeth on helical gears, they create a thrust load on the gear when they mesh. Devices that use helical gears have bearings that can support this thrust load. One interesting thing about helical gears is that if the angles of the gear teeth are correct, they can be mounted on perpendicular shafts, adjusting the rotation angle by 90 degrees. WORM GEAR: A short rotating screw that meshes with the teeth of another gear. As a worm gear is an inclined plane, it will be the driving gear in most cases. Worm gears are used when large gear reductions are needed. It is common for worm gears to have reductions of 20:1, and even up to 300:1 or greater. Many worm gears have an interesting property that no other gear set has: the worm can easily turn the gear, but the gear cannot turn the worm. This is because the angle

on the worm is so shallow that when the gear tries to spin it, the friction between the gear and the worm holds the worm in place. This feature is useful for machines such as conveyor systems, in which the locking feature can act as a brake for the conveyor when the motor is not turning. One other very interesting usage of worm gears is in the Torsen differential, which is used on some high performance cars and trucks. BEVEL GEAR: Bevel gears are used to connect shafts, which intersect usually but not necessarily at 90 degrees. The teeth on a bevel gear are subjected to much the same action as spur gear teeth. Bevel gears are not interchangeable and in consequence are designed in pairs (except in the case of mitre bevel gears). DIFFERENTIAL GEAR: A certain arrangement of gears connecting two axles in the same line and dividing the driving force between them, but allowing one axle to turn faster than the other. It is used in the rear axles of automobiles to permit a difference in axle speeds while turning. RACK GEAR: A toothed bar into which a pinion, (worm gear spur etc.) meshes. Rack and pinion gears are used to convert rotation into linear motion. A perfect example of this is the steering system on many cars. The steering wheel rotates a gear, which engages the rack. As the gear turns, it slides the rack either to the right or left, depending on which way you turn the wheel PINION: A small cogwheel, the teeth of which fit into those of a larger gearwheel or those of a rack. COGWHEEL: A wheel with a rim notched into teeth, which meshes with those of another wheel or a rack to transmit or receive motion.

4. GEAR TERMINOLOGY

Fig 1 Gear Specification DEFINITIONS: 1. Addendum: The distance a tooth projects above, or outside of, the pitch line or circle. 2. Base circle: The base circle is a circle from which involute tooth profiles are derived. 3. Base cylinder: The base cylinder corresponds to the base circle and is the cylinder from which involute tooth surfaces, either straight or helical are derived. 4. Backlash: The amount by which the width of a tooth space exceeds the thickness of the engaging tooth on the operating pitch circles. Backlash is the gap between gear teeth where they mesh. This leads to play in the gears. 5. Bottom Land: The root diameter. 6. Chordal Addendum: The distance from the outer diameter to the pitch line.

7. Chordal Thickness: The tooth thickness at the pitch line. 8. Circular Pitch: The distance from the center of one tooth to the center of the next tooth measured round the circumference of the pitch circle. 9. Clearance: The amount by which the Dedendum of a gear tooth exceeds the addendum of a mating gear. 10. Center distance: The distance from the center of the gear shaft to the center of the pinion shaft. 11. Circular tooth thickness: The length of arc between the two sides of the same gear tooth, on a specified circle. (Refer figure 1). 12. Datum circle: The datum circle is a circle on which measurements are made. 13. Composite action test: A method of gear inspection in which the work gear is rolled in tight, double-flank contact with a master gear or a specified gear to determine composite variations. 14. Composite tolerance, tooth-to-tooth (double-flank): The permissible amount of tooth-to-tooth composite variation. 15. Composite tolerance, total (double-flank): The permissible amount of total composite variation. 16. Composite variation: Variation in center distance when a gear is inspected by a composite-action test. 17. Composite variation, tooth to tooth (double-flank): The greatest change in center distance while the gear being tested is rotated through any angle of 360/N during a double flank composite test.

18. Total Composite variation (double-flank): The total change in center distance while the gear being tested is rotated one complete revolution during double-flank composite-action test. 19. Datum of axis rotation: The axis of the gear used as the basis for measurements. 20. Datum tooth: The designated tooth used as the starting point for measuring other teeth. 21. Diameter, profile control: The specified diameter of the circle beyond which the tooth profile must conform to the specified involute curve. 22. Dedendum: The depth of a tooth space below, or inside of, the pitch circle. 23. Eccentricity: The distance between the center of a datum circle and a datum axis of rotation. 24. Face width: The length of the gear teeth in an axial plane. 25. Functional face width: The portion of the face width less the edge round at each end. 26. Index variation: The displacement of any tooth from its theoretical position, relative to a datum tooth. Measurements are usually linear, near the middle of the functional tooth profile. If the measurements are made normal to the tooth surface, they should be corrected to the transverse plane. 27. Total Index variation: The maximum algebric difference between the extreme values of index variation for a given gear. Total index variation is also equivalent to total accumulated pitch variation measured by a two probe spacing system. 28. Lead: The axial advance of a helix for one revolution, (see Fig.2).

Fig 2 Tooth Thickeness 29. Master gear: A gear of known quality that is used to perform a compositeaction test. 30. Outside diameter: The diameter of the addendum circle (outside) of a cylindrical gear. 31. Pitch: The distance between similar, equally spaced tooth surfaces along a given line or arc. (See Fig 3).

Fig 3 Lead (top) and various pitches (bottom).

32. Axial pitch: The pitch of a gear parallel to the axis of rotation. 33. Base pitch: On an involute gear, the base pitch is the pitch on the base circle or along the line of action. It is equal to the circumference of the base circle divided by the number of teeth. 34. Circular Pitch: The distance along a specified pitch circle or pitch line between corresponding profiles of adjacent teeth. (See Fig. 3)

35. Diametral pitch: The diameter of the pitch circle. The ratio of the number of teeth to the pitch diameter in the transverse. It is equal to pi divided by the circular pitch.

36. Normal diametral pitch: The ration of the number of teeth to the pitch diameter in the normal plane of a helical gear. The normal plane and transverse of a spur gear are coincident. 37. Pitch variation: The plus or minus difference in the transverse plane between the average measured pitch and the actual pitch measurement. (See Fig. 4)

Fig 4 Pitch Variation.

38. Pressure Angle: The angle between a tooth profile and a radial line at its pitch point. It is usually equal to 20 degrees. 39. Normal pressure angle: The angle at a point on the pitch cylinder between the line of pressure that is normal to the tooth surface and the plane tangent to the pitch cylinder. 40. Profile: One side of a tooth in a cross section between the out side circle and the rootcircle.

Fig 5 Profile 41. Functional profile: The portion of the tooth flank between the profile control diameter and the addendum circle or the start of tip round.

Fig 6 Functional profile

42. Profile variation: The difference between the measured and the specified functional profile. If measured in a normal plane, a correction using the appropriate helix angle must be applied to the measured value.

Fig 7 Profile Variation. 43. Profile tolerance: The permissible amount of profile variation in the functional profile; designated by a specified K chart envelope as shown in figure 8. Plus material at the tip, which increases the amount of variation outside the functional profile, is not acceptable. Minus material beyond the start of tip can be disregarded.

MEASUREMENT OF GEAR ACCURACY The methods of testing and measuring gears depend largely on the class of gear, the method of manufacture, and the equipment available. Because even the smallest out-of- spec gear can halt operations, gear manufacturers have many inspection options for both functional and analytical evaluation. Functional gaging, or attribute inspection, offers a quick, go or no-go method to check whether a gear is good or bad, and whether it will function as intended. To determine

whether a part meets dimensional specifications, gear manufacturers rely on analytical testing. Such analysis is reserved for trouble shooting situations when a manufacturer is looking for the source of a problem in the gear machining process The numbers of instrumentation options for both types of dimensional test make deciding on the correct measurement solution dicey. The correct system depends on the type of gear being measured and the application for which it is intended. Gears with parallel axes are much simpler to gage than those with cross axes, and require a standard, rather than customized, solution. Similarly, if a manufacturer is held to strict, tight tolerances on a gear for use in a medical device, then accuracy will determine the choice. In terms of application, do you want to control your manufacturing process or inspect a gear to specifications? Depending on the answer, youll need a functional or analytical measurement system. FUNCTIONAL GEAR CHECKING Functional testing is a qualitative form of inspection to determine whether a gear will work as intended. The most basic form of functional gear test equipment involves a single-flank or double-flank meshing arrangement between a master gear and a production gear. Another checking methods related to functional checking is tooth contact or bearing pattern checking. Functional or composite gear checking involves rolling two gears together and measuring the resultant motion. The gears rolled together can be either work and master gears or two work gears. Single-flank configurations display transmission errors of only one flank at a time. Double-flank models display center distance variation and the performance of both flanks simultaneously. Double-flank gear testers expose radial eccentricity or outof-round errors, but they dont detect angular tooth position defects, which can be a source of transmission errors. These testers can find nonsystematic errors,

including burrs, nicks, or hard spots, and they enable an inspector to determine functional tooth thickness. To use a basic functional gear tester, the operator mounts a gear on a spindle, brings it to zero backlash mesh, and rotates it for one revolution of the production gear. He can then determine center distance variation between the gears. Manually operated systems enable in-process auditing and provide quick visual verification that the gear falls within specifications. For a test thats free of operator influence, and is faster in analysis throughput, computerized models are a better option. Computerized systems can separate measurements into their finer elements. If we want to know just the runout characteristic of a gear, and separate the tooth-to-tooth rolling action, we need a computerized model to do that. The computer can separate and give value for runout, tooth-to-tooth, and maximum and minimum defects. If we try to read those elements with a dial indicator [a manually operated gear checker], they would flash so fast that our eyes could never see them.

5.COMPONENTS OF N-SEREIES GEAR BOX

In our project the following components are involved to achieve the indefinite speed. 1. Structure 2. Flat belt
3. Plummer block

4. Roller 5. Screw rod 6. Ball bearing 7. Handle

5.1 STRUCTURE
Structural steel is steel construction material, a profile, formed with a specific shape or cross section and certain standards of chemical composition and strength. Structural steel shape, size, composition, strength, storage, etc, is regulated in most industrialized countries. Structural steel members, such as I-beams, have high second moments of area, which allow them to be very stiff in respect to their cross-sectional area. A steel I-beam, in this case used to support wood beams in a house.

Structural steel in construction: A primed steel beam is holding up the floor above, which consists of a metal deck (Q-Deck), upon which a concrete slab has been poured. Steel beam through-penetration with incomplete fireproofing. Metal deck and OWSJ (Open Web Steel Joist), receiving first coat of spray fireproofing plaster, made of polystyrene leavened gypsum. Contents 1 Common structural shapes 2 Standards 2.1 Standard structural steels 2.2 Standard structural steels 2.2.1 Carbon steels 2.2.2 High strength low alloy steels 2.2.3 Corrosion resistant high strength low alloy steels 2.2.4 Quenched and tempered alloy steels 3 Steel vs. concrete 4 Thermal properties 5 Fireproofing of structural steel

COMMON STRUCTURAL SHAPES In most developed countries, the shapes available are set out in published standards, although a number of specialist and proprietary cross sections are also available.

I-beam (I-shaped cross-section - in Britain these include Universal Beams (UB) and Universal Columns (UC); in Europe it includes the IPE, HE, HL, HD and other sections; in the US it includes Wide Flange (WF) and H sections) Z-Shape (half a flange in opposite directions) HSS-Shape (Hollow structural section also known as SHS (structural hollow section) and including square, rectangular, circular (pipe) and elliptical cross sections) Angle (L-shaped cross-section) Channel ( [-shaped cross-section) Tee (T-shaped cross-section) Rail profile (asymmetrical I-beam) Railway rail Vignoles rail Flanged T rail Grooved rail Bar a piece of metal, rectangular cross sectioned (flat) and long, but not so wide so as to be called a sheet. Rod, a round or square and long piece of metal or wood, see also rebar and dowel. Plate, sheet metal thicker than 6 mm or 1/4 in. Open web steel joist While many sections are made by hot or cold rolling, others are made by welding together flat or bent plates (for example, the largest circular hollow sections are made from flat plate bent into a circle and seam-welded). Standard structural steels

Most steels used throughout Europe are specified to comply with the European standard EN 10025. However, many national standards also remain in force. Typical grades are described as 'S275J2' or 'S355K2W'. In these examples, 'S' denotes structural rather than engineering steel; 275 or 355 denotes the yield strength in newtons per square millimetre or the equivalent megapascals; J2 or K2 denotes the materials toughness by reference to Charpy impact test values; and the 'W' denotes weathering steel. Further letters can be used to designate normalized steel ('N' or 'NL'); quenched and tempered steel ('Q' or 'QL'); and thermo mechanically rolled steel ('M' or 'ML'). The normal yield strength grades available are 195, 235, 275, 355, 420, and 460, although some grades are more commonly used than others e.g. in the UK, almost all structural steel is grades S275 and S355. Higher grades are available in quenched and tempered material (500, 550, 620, 690, 890 and 960 - although grades above 690 receive little if any use in construction at present). ] Thermal properties The properties of steel vary widely, depending on its alloying elements. The austenizing temperature, the temperature where a steel transforms to an austenite crystal structure, for steel starts at 900C for pure iron, then, as more carbon is added, the temperature falls to a minimum 724C for eutectic steel (steel with only .83% by weight of carbon in it). As 2.1% carbon (by mass) is approached, the austenizing temperature climbs back up, to 1130C. Similarly, the melting point of steel changes based on the alloy.

The lowest temperature at which a plain carbon steel can begin to melt, its solidus, is 1130 C. Steel never turns into a liquid below this temperature. Pure Iron ('Steel' with 0% Carbon) starts to melt at 1492 C (2720 F), and is completely liquid upon reaching 1539 C (2802 F). Steel with 2.1% Carbon by weight begins melting at 1130 C (2066 F), and is completely molten upon reaching 1315 C (2400 F). 'Steel' with more than 2.1% Carbon is no longer Steel, but is known as Cast iron. http://www.msm.cam.ac.uk/phase-trans/images/FeC.gif ] Fireproofing of structural steel In order for a fireproofing product to qualify for a certification listing of structural steel, through a fire test, the critical temperature is set by the national standard, which governs the test. In Japan, this is below 400C. In China, Europe and North America, it is set at ca. 540C. The time it takes for the steel element that is being tested to reach the temperature set by the national standard determines the duration of the fire-resistance rating. Care must be taken to ensure that thermal expansion of structural elements does not damage fire-resistance rated wall and floor assemblies. Penetrants in a firewalls and ferrous cable trays in organic firestops should be installed in accordance with an appropriate certification listing that complies with the local building code.

5.2 INTRODUCTION OF FLAT BELT DRIVE Definition : The power or energy produced in one machine can be transmitted to another machine or between two members of a machine by means of some intermediate mechanisms called drives. Classification of Flat belt drives: Depending upon the use, the flat belt drives are classified into the following categories: 1) Open belt drive: In this type, the shafts of driving and driven members are kept parallel and the direction of rotations of both pulleys are same. The line joining the centres of pulleys may be horizontal, vertical or inclined. Open Belt Drive 2) Cross or twist belt drive: Here the shafts are kept parallel but the directions of rotations of pulleys are opposite to each other. (3) Quarter-turn drive: In this case, the axes of pulleys are arranged at right angles to each other. The drive is sometimes provided with an idler pulley so as to maintain the required arc of contact. (4) Belt drive with an idler pulley : Here .a small extra pulley is operated in the slack side of the belt drive apart from the

usual pulleys (i.e., driving and driven pulleys) for increasing the arc of contact and thus the power transmission is properly maintained. (5) Belt drives with many pulleys: Here many pulleys are operated by a single belt so that many operations are carried out at a time. DESIGN OF FLAT BELTS: The essential parameters of flat belt like width, thickness, length and the type of belt are determined based on two methods. 1. Using Fundamental formulas. 2. Using Manufacturers catalogs 1. Using fundamental formulas : When the driving pulley rotates the driven pulley by belt, the belt pulling side is known as tight side and the belt releasing side is known as slack side. If the centre distance and the selected materials of belt and pulleys are kept proper, the belts can have sufficient grip over the pulley without any slip and the power transmission is properly maintained. For designing the belt based on fundamental formulae, we should know the tensions (i.e,. loads) on tight side and slack side of the pulleys, power-torque relationship, coefficient of friction between the contact surfaces of pulleys and belt, diameters of pulleys and so on. Design of belts by this method is based mainly on two concepts. 1. How much power (i.e., Maximum power (or) Design power) to be transmitted. 2. What may be the power transmitting capacity (i.e., belt rating) of the selected belt.

Arc of contact: Consider the driving pulley and the driven pulley are connected by a flat belt as shown in fig. The angle subtended by the overlaying belt on the pulley is known as angle of contact or arc of contact (). Let d = Diameter of smaller pulley D = Diameter of bigger pulley C = Centre distance between pulleys.

5.3 PLUMMER BLOCK Early pillow-block with bearing. A pillow block, also known as a plumber block[1] or bearing housing, is a mounted plain or roller bearing used to provide support for a rotating shaft with the mounting surface on a parallel line with the axis of the shaft. Housing material for a pillow block is typically made of cast iron or pressed steel. Pillow blocks are extensively used in conveyor systems such as tube chain conveyors. Pillow blocks are usually referred to the housings which have a bearing fitted into them & thus the user need not purchase the bearings separately. Pillow blocks are usually mounted in cleaner environments & generally are meant for lesser loads of general industry. These differ from "plummer blocks" which are bearing housings supplied without any bearings & are usually meant for higher load ratings & corrosive industrial environments. However fundamental application of both types is the same which is to primarily mount bearings safely enabling their outer ring to be stationary usually and allowing rotation of the inner ring. The housing is bolted to a foundation through the holes in the base. Bearing housings are either split type or unsplit type. Split type housings are usually two piece housings where the cap and base can be detached. While certain series are one single piece housings. Various seals are provided to prevent dust and other contaminants from entering the housing. Thus the housing provides a clean environment for the expensive bearings to freely rotate hence increasing their performance and duty cycle. Large bearing housings are usually made of grey cast iron. However various different grades of metals can be used to manufacture the same. Small and lowcost housings are die-cast in zinc or aluminium alloys.

5.4 BEARINGS INTRODUCTION Bearing is a stationery machine element which supports a rotating shafts or axles and confines its motion. Naturally, a bearing will be required to offer minimum frictional resistance to moving parts so as to result in minimum loss of power. In order to reduce frictional resistance, a layer of fluid may be provided. CLASSIFICATION OF BEARING Bearings are mainly classified as follows. (i) Depending upon the type of load coming upon the shaft: In radial bearings, the load acts perpendicular to the direction of Of moving parts (i.e. Shaft). It is shown in fig. 4.4.1. A) Radial bearing. B) Thrust bearings. In thrust bearings the pressure acts along or parallel to the axis of the shaft. (iii) Depending upon the nature of contact: A) Sliding contact B) Rolling contact bearings or Antifriction bearings. In sliding contact bearings, the shaft rotates in a bearing and there are no interposed elements between shaft and bearings. There is a direct contact between shaft and bearings. In rolling contact bearings, the steel balls or rollers are provided in between shaft and bearings to reduce friction. BEARING MATERIALS

Bearing material should have the following properties. I) High compressive strength Ii) Low coefficient of friction Iii) High thermal conductivity Iv) High resistance to corrosion V) Sufficient fatigue strength Vi) It should be soft with a low modulus of elasticity Vii) Bearing materials should not get weld easily to the journal material. (i) Lead base contains: It contains Lead-74%, Antimony- 15%, Tin- 1%, Arsenic-O. 5% and Cu-O.25%. It has excellent resistance to seizure and has good corrosion resistance its compressive strength and hardness decrease rapidly with an increase in temperature. Therefore it should not be used above 1150. It is used for split bushings made from strip or gravity cast bearings. (U) Tin base habit: It contains Tin-89%, Antimony-7.5% and Copper-3.25%. It is slightly harder than lead habit at room temperature. It has excellent anti-series deformability and acid-resisting properties. It is also Used for split bushings. (iii) Leaded bronze: The compositions and use of leaded bronze are as follows. Cu 80% Tin 10%, Lead-l0% it used for split bushings made 4 From strip or gravity cast bears. 4 These are having excellent Fatigue life and are capable of Carrying heavy loads at high Temperatures. Cu-72%, Tin-3%, Lead-23% Use for split bushings and hail

Beings made from strip or Gravity cast bearings. (iv) Copper lead alloy: The compositions and uses of copper lead alloy are as follows. Cu-65%, Lead 35% Use for split bushings and half Bearings made from strip or Gravity cast bearings Cu-71%, Lead-28%, Silver-l% Used for gravity cast bearings these are having excellent fatigue life and capable of carrying heavy leads at high temperatures. But they are having poor erosion resistance compared to Habit (v) Gun metal: Its composition is as follows. Copper-88%, Tin-l0%, Zinc-2%. It is used for high-grade bearings subjected to high pressure and high speeds. (vi) Phosphor bronze: Superior fatigue resistance. (x) Plastics: Composition is Copper-80%, Tin- 10%, Lcad-9%, Phosphores- 1%. It is used for bearings subjected to very high pressures and speeds. (vii) Cast Iron: It is used with steel journals. It should be provided with adequate lubricant. It is used for low pressure and low speed bearings. (viii) Aluminum alloy: Its composition is Al-92%, Cu-l%, Tin-6%, Ni-1% It is used for cast or forged solid construction. It has better fatigue resistance but poor surface behavior. (ix) Silver: The usual form of construction is clectro- plated bearing used with lead-tin or leadindium overlay. It has excellent corrosion resistance and

The common commercial plastics used for bearings are Nylon and Teflon. These may be used as zero film bearings. These have high fatigue strength, hardness and more resistant to abrasive wear.

5.5 SCREW ROD SCREW THREAD MEASUREMENT v Screw threads are used to transmit the power and motion, and also used to fasten two components with the help of nuts, bolts and. studs. v There is a large variety of screw threads varying in their form, by included angle, head angle, helix angle etc. v The screw threads are mainly classified into 1) External thread 2) Internal thread. External thread Internal thread SCREW THREAD TERMINOLOGY 1) Screw thread: It is a continuous helical groove of specified cross-section produced on the external or internal surface. 2) Crest: It is top surface joining the two sides of thread. 3) Flank: Surface between crest and root. 4) Root: The bottom of the groove between the two flanks of the thread 5 Lead: Lead = number starts x pitch 6,) Pitch: The distance measured parallel to the axis from a point on a thread to the corresponding next point.

7) Helix angle: The helix is the angle made by the helix of the thread at the pitch line with the axis. 8) Flank angle: Angle made by the flank of a thread with the perpendicular to the thread axis. 9) Depth of thread: The distance between the crest and root of the thread. 10) Included angle: Angle included between the flanks of a thread measured in an axial plane. 11) Major diameter: Diameter of an imaginary co-axial cylinder which would touch the crests of external or internal thread. 12) Minor diameter (Root diameter or Core diameter): Diameter of an imaginary co-axial cylinder which would touch the roots of an external thread. 13).Addendum Radial distance between the major and pitch cylinders For external thread. Radial distance between the minor and pitch cylinder For internal thread. 14) Dedendum: v Radial distance between the pitch and minor cylinder = For external thread. v Radial distance between the major and pitch cylinders = For internal thread.

THREAD DATA S.NO Forms of thread 1 British standard whitworth BSW Shape of thread Symmetrical V Angle between flankes in deg 55 Bolt and screw and fatening parts subjected to vibration in aero and auto parts. 2. British association 3 thread BA American national standard thread 4 Unified standard thread Symmetrical V Symmetrical V with flat crest and root Symmetrical V with rounded crest and root 60 60 47.5 Instruments and precision works General purpose Example bolts, nuts screw and tapped holes Used in Brittan Canada and US. Application

Square thread

Square

Perpendicular to axis of thread

Power transmission used in machine tools valves spindle and screw jack

Acme thread

Modified form of Square thread Rounded top and bottom Both square and V Similar to BSW thread

29

Screw cutting,lathesbrass valves, cocks and bench vices. Rail way carriage couplings hydrants neck of class bottles. Spindles of bench vices Fastening application

Knuckle thread

8 9

Butters thread Metric thread

45 60

6.DESIGN ASPECTS AND OPERATION PROPERTIES OF MILD STEEL : PHYSICAL PROPERTY: Density Melting point - 7860 Kg/m3 - 1427c

Thermal conductivity - 63 W/ m K CARBON CONTENT: Low Carbon (or) Mild steel - 0.15% to0.45% carbon MECHANICAL PROPERTY: Elasticity Ductility Toughness Weld ability In our design, screw type clamp, Body of jig have a main part hence the calculations are concentrated on it

OPERATIONS INVOLVED: Turning (facing, plain turning, step turning , threading etc) Facing (flat surface) Drilling Gas cutting (flat plate, cylindrical rods) Shaping Welding Tapping Thread cutting

TURNING: Turning is the operation of reducing a cylindrical surface by removing material from the outside diameter of a work piece. It is done by rotating the work piece about the lathe axis and feeding the tool parallel to the lathe axis. Due to this operation screw rod and head are done by the turning operation to get the required shape. FACING: Machining the end of the work piece to produce flat surface is called facing. Due to this, the plate can get flat surface have done by the facing operation.

DRILLING: Drilling is the operation of producing cylindrical hole in work piece. It is done by rotating the cutting edge of the cutter known as drill bit. In this Project the jig plates require holes for locating indexing plate and screw rod, drill bush assembly. These holes are done by conventional vertical drilling machine. THREAD CUTTING: Thread cutting is the operation of forming external thread of required diameter of rod by using a multipoint tool is called thread. This process is used in screw clamp to done on the rod which is used for the movement of the movable plate

Fine grinding It is nothing but the grinding process, which is done as smooth with fine grains. This is done as the each plate and base plate for good surface finish. It is done by conventional grinding machine.

Gas cutting

It is used to break are cut the plates. In this project it is used

to cut the raw materials such as plates. This done by gas cutting machine.

Shaping

Shaping operation is used to reduce the dimensions of the plates. In this project the plates are in need of shaping process. It is done by shaping machine. Welding It is the process, which is used to join two, is more similar materials as well as dissimilar materials. In this project it is used to join the jig plate one to another. This is done by arc welding machine.

7. ADVANTAGES AND APPLICATIONS ADVANTAGES

It is used for to achieve different speed by simple mechanism.

Its operation and maintenance is very simple. It is compact and portable. It is simple and rigid in construction.

Manufacturing cost is lesser than other gear boxes. It provides better speed changes method on the driving unit.

5.2 APPLICATIONS This device find place in almost all types of industries (Large, Small, medium scale industries).

This device is mainly used in wherever different speed need This device is suitable for fine speed changes aswellas to achieve rapid speed changes.

7.1. PROCESS CHART Part name 1.Stucture Operations The M.S plate of rough size is cut, drilled & shaped to finish size The M.S square of rough size 2.Plummer is cut, drilled & shaped to block finish size The M.S square of rough size 3.Bearings is cut, drilled & shaped to finish size The M.S rod is turned, faced, 4.screw rod threaded & drilled to require diameter. The round log is cut to 5. Roller require size, drilled ,taper turnedto required dia & shaped to finish size The M.S square is cut to 6.Equaliser require size, drilled to plate required dia & shaped to finish size For assembling of parts, welding has been done where ever necessary 7.2 Design process Gas cutting m/c Shaping m/c Drilling m/c Mild steel Lathe Drilling& Threading m/c Mild steel Mild steel Gas cutting m/c Drilling m/c Mild steel Machine used Materials used

Mild steel

Drilling m/c Turning

Rose wood

PRIMARY CUTTING PROCESS The processes used for preliminary cutting of the component are known as primary cutting process. The common operations involved in this process are gas cutting, sawing etc. MACHINING PROCESS The process used for giving final shape to the component according to the planned dimension is known as machining process. The common processes involved in this process are turning, planning, shaping, drilling, etc. SURFACE FINISHING PROCESS The process used to provide a good surface finish for the components are called as surface finishing process. The common operations used for this process are polishing, buffing, abrasive belt grinding, super finishing, etc. JOINING PROCESS The processes used to join the components are known as joining process. The common operations used for this process are welding, riveting, screw fastening, drilling etc.

7.3 GENERAL PROCEDURE OF DESIGN REGOGANISATION OF NEED First, make a complete statement of the problem, indicating the need, aim or purpose for which is to be designed. SYNTHESIS (MECHANISM) Select the possible mechanism or group of mechanism which will give the desired motion. ANALYSIS OF FORCES

Find the forces acting on the each member of the machine and energy transmitted by the each member. MATERIAL SELECTION Select the material best suited for each member of the machine. DESIGN OF ELEMENTS (SIZE AND STRESSES) Find the size of each member of the machine by considering the forces acting on the member and the permissible stress for the material used. It should be kept in the mind that each member should not deflect or deform then the permissible limit. MODIFICATION Modify the size of the member to agree with the past experience and judgment to facilitate manufacture. The modification may also be necessary by consideration of manufacturing to reduce overall cost. DETAILED DRAWING Draw the detailed drawing of each component of each assembly of the machine with complete specification for the manufacturing process suggested. PRODUCTION The component, as per the drawing, is manufactured in the workshop.

8.COST ESTIMATION

S.NO 1. 2. 3. 4. 5. 6 7

Name of the part Structure roller Plmmer block Screw rod M16 screw rod Bearing Handle

Weight in kg 7 2 2 1 2 1

Cost RS. 680 760 375 250 100 150 175

TOTAL = 2490.00

LABOUR COST Lathe, drilling, shaping, welding, riveting, turning, painting, surface grinding and gas cutting. Cost = Rs 1800.00

10.2. TOTAL COST Total cost = material cost + Labour cost = 2490 + 1800 = 4290.00

Total cost for this project = Rs 4290.00

9.DIAGRAM OF N-SERIES GEAR BOX

CONCLUSION This report details with design of Nseries gear box is attached with the Part drawings. The project carried out by us made an impressing task in the Manufacturing works. It is very useful for the speed controlling areas.This project has been designed to perform the entire requirement task, which has also been provided.

BIBLOGRAPHY

1. Jig and fixture design by EDWARD.G.HOFFMAN. 2. Jigs and fixtures by P.H.JOSHI. 3. Work shop technology by R.S. KHURMI. 4. Engineering practice by R.K. NATARAJAN. 5. Machine tools (vol.2) by S.K. HAJRA CHOUDRY. 6. Design data by P.S.G. COLLEGE OF TECHNOLOGY.