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Design of a Shredder

Amandeep Singh

18583364

A report submitted for 300597 Master Project 1


in partial fulfilment of the requirements for the degree of Masters of
Engineering (Mechanical)

Supervisor: XXX

School of Computing, Engineering and Mathematics

Western Sydney University


October 25, 2017
ACKNOWLEDGMENTS

I would like to express my appreciation to my classmates and my supervisor, who helped


me in deep understanding of this concept. I want to thank my friend Sagar and Karan for
helping me learn ANSYS and SolidWorks which was very necessary for completion of
this report of my Master Project 1.

My supervisor Helen Wu have deep knowledge about vibrations and I also want to do
some research regarding this topic so this was the reason for opting her as my supervisor
for this project .Through the project she helped me a lot .She showed me the way to
pursue my research into this topic. I want to thank her as she was very supportive through
this semester.

Amandeep Singh
18583364

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TABLE OF CONTENTS

Chapter Page

ACKNOWLEDGMENTS ................................................................................................... i
TABLE OF CONTENTS .................................................................................................... ii
LIST OF TABLES .............................................................................................................. 1
CHAPTER I: INTRODUCTION AND BACKGROUND ................................................. 2
1.1 Shredder Design Parameters ..................................................................................... 3
CHAPTER II: AIMS AND OBJECTIVES ........................................................................ 5
CHAPTER III: SHREDDER DESIGN .............................................................................. 6
3.1. Gear Drive Design ............................................................................................ 6
3.2. Gear Design ...................................................................................................... 9
3.3. Body Design ................................................................................................... 15
3.4. Cutter Design .................................................................................................. 17
3.5. Cutter Assembly ............................................................................................. 19
3.6. Safety Features ............................................................................................... 19
CHAPTER IV: FEM SIMULATION ............................................................................... 21
4.1. Geometry for FEM Simulation ....................................................................... 21
4.2. FEA Modeling Details .................................................................................... 22
4.3. Load Cases ...................................................................................................... 22
4.4. Boundary Conditions ...................................................................................... 23
4.5. Simulation Results .......................................................................................... 23
4.5.1. Modal Analysis ............................................................................................... 24
4.5.2. Choking on Left Cutter ................................................................................... 24
4.5.3. Choking on Center Cutter ............................................................................... 25
4.5.4. Choking on Right Cutter................................................................................. 26
4.6. Discussion of Simulation Results ................................................................... 26
CHAPTER V: CONCLUSION......................................................................................... 27
REFERENCES ................................................................................................................. 28

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LIST OF FIGURES
Figure 1: Accumulated Trash for Recycling ....................................................................... 2
Figure 2: Identification of Recyclable materials ................................................................. 3
Figure 3: A hand powered shredder concept ...................................................................... 6
Figure 4: Gear Drive Design-1 ........................................................................................... 7
Figure 5: Gear Drive Design-2 ........................................................................................... 8
Figure 6: Gear 1 Position and Design ................................................................................. 9
Figure 6: Gear-1 Drawing ................................................................................................. 11
Figure 8: Gear 2 Position and Design ............................................................................... 12
Figure 9: Gear-2 Drawing ................................................................................................. 13
Figure 10: Gear 3 Position and Design ............................................................................. 14
Figure 11: Gear-3 Drawing ............................................................................................... 15
Figure 12: Shredder Body Design..................................................................................... 16
Figure 13: Shredder Components a) Hopper (Top Left) b) Drive Shaft (Top Right) c)
Gear Cover (Bottom Left) d) Motor Cover (Bottom Right) ............................................. 16
Figure 14: Shredder Dimensions ...................................................................................... 17
Figure 15: Cutter Design ................................................................................................... 18
Figure 16: Cutter Drawing ................................................................................................ 18
Figure 17: Cutter Assembly .............................................................................................. 19
Figure 18: Safety Features ................................................................................................ 20
Figure 19: FEM Geometry ................................................................................................ 21
Figure 20: FEM Model Details ......................................................................................... 22
Figure 21: Position of Cutters for Load Cases .................................................................. 22
Figure 22: Boundary Conditions ....................................................................................... 23
Figure 23: Results of Modal Analysis .............................................................................. 24
Figure 24: Results of Choking on Left Cutter .................................................................. 25
Figure 25: Results of Choking on Center Cutter .............................................................. 25
Figure 26: Results of Choking on Right Cutter ................................................................ 26

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LIST OF TABLES

Table 1: Gear Drive Calculations-1 .................................................................................... 7


Table 2: Gear Drive Calculations-2 .................................................................................... 8
Table 3: Gear Design Sheet-1 ........................................................................................... 10
Table 4: Gear Design Sheet-2 ........................................................................................... 12
Table 5: Gear Design Sheet-3 ........................................................................................... 14
Table 6: Load Cases for Cutter Choking .......................................................................... 23

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CHAPTER I: INTRODUCTION AND BACKGROUND

A shredder is a machine used to break anything into small pieces. It can be designed for
many things like paper, glass, plastic, metal, concrete etc. A hand-powered mini shredder
using gear drives was especially designed for recycling thermoplastics, i.e., ABS
(acrylonitrile butadiene styrene) and PLA (Polylactic acid).

Figure 1: Accumulated Trash for Recycling

In today’s world there is an urgent requirement of recycling so that the same material can be
used multiple times without wasting our limited resources. The first step in the recycling
process is breaking the material into small chunks so that it can be transported and fed in to
the recycling machine and process.

For recycling the waste materials like polymer and metal materials that are generated in our
college 3D printing laboratory, a shredder is required. This design is taken as the project
work using the design principles, Engineering skills and technical tool knowledge to design
an efficient, safe, secure and durable shredder. The compact shredder needs to cut the waste
to the size of 5mmX5mmX5mm pieces for recycling.

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Figure 2: Identification of Recyclable materials

The recycling materials always have a mark below them to identify if they are reusable or not
as shown in figure 2 above. After they are used for defined number of times, they should be
discarded separately so that the materials should reach the proper recycling units.

1.1 Shredder Design Parameters

PURPOSE: To crush, shred and grind thermoplastic wastes fine enough with a size of
5mmX5mm.
The following design parameters were the input provided for the design of the shredder.
Based on these, all the calculations were done and the design was prepared.

 The shredder could run at a speed of 60 rpm and need a torque of 500 Nm at
most to crush, shred and grind thermoplastic wastes. Both of them are permitted
to vary 5%.

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 A stage of speed reducer is preferred but one stage is also acceptable. The speed
reduction ratio of the speed reducer should be controlled in a range of 3.46 to
3.53 for each stage.
 A compact design is required to integrate the speed reducer with the shredder
together with an overall size of 0.5m X 0.3 m X 0.3 m.
 A mechanical efficiency of greater than 95% is desirable.

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CHAPTER II: AIMS AND OBJECTIVES

The aim of this Design Task is to narrow down the gap between fundamental theories and
practical applications of Finite Element Method (FEM) and Finite Element Analysis (FEA)
on Computer Aided Engineering through synergistically and systematically applying what we
have learning and are going to learn in this unit 301022 Advanced Computer Aided
Engineering to design a typical mechanical device – a shredder to perform a design practice
and finish design loops in the assessment task – CAE Design Project.

The design includes the concept design based on the given criteria, the CAD design work
using SolidWorks, Simulation using ANSYS, design recommendation based on the FEM
results and a design report.

The shredder is designed considering the following parameters for the overall design at
each design stage.
 Safety: The shredder should operate safely and provide a safe environment for
people near the machine.
 Cost: Low cost is desirable so that the shredder appeals to a large set of
customers.
 Size: compact design with a small size is preferred.
 High reliability.
 Low maintenance.
 Smooth operation: low noise and vibration.

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CHAPTER III: SHREDDER DESIGN

The shredder design included the following steps in designing a light usable machine that
solves its purpose using cheap and available resources and easily manufacturable.
1. Gear Drive Design including motor selection.
2. Gear Design
3. Body Design
4. Cutter Design
5. Cutter Assembly
6. Simulation and Design Changes

The following steps were done in detail as explained below step by step.

Figure 3: A hand powered shredder concept

3.1. Gear Drive Design

The design of the Gear Drive was the primary step as the dimensions and the layout of
the shredder body is depended on the gears and its assembly. For designing this, the excel
sheet is used, all the relations and the constraints mentioned in the design specifications
are added in this.
After looking at the design, 2 options were obtained from the calculations as shown
below.

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3.1.1. Gear Drive 1
The first option was to use 2 gears as shown in figure 4 below. The drive was to be driven
by using an electric motor, can be adjusted below the small gear.

Figure 4: Gear Drive Design-1

2 Gear MOTOR
Input rpm 210 rpm
Input Power 2(pi)NT/60 3 kW High Power
4.02306 HP
Input Torque 136.4877 Nm
PCD of Gear 1 0.06 m
Force on Gear 1 4549.591 N

Gear Ratio 3.46 Fixed


Meeting
RPM on Gear 2 60.69364
Criteria
PCD of Gear 2 0.2076 m
Meeting
Torque on Gear 2 472.2475 Nm
Criteria

Radius of Cutter 0.0375 m


Force on Cutter 12593.27 N

Table 1: Gear Drive Calculations-1

The problem in this design option is that the rpm of the motor selected is very less
i.e. 210rpm and the tentative cost of the motor’s with low speed is comparatively
high.

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3.1.2. Gear Drive 2
In the second layout, the 3 gears were used to design the gear drives as shown in the
figure 5 below. Since the gear ratio of the gears are fixed in the specifications i.e. 3.46 to
3.53, considering that, the size of the 3rd gear comes out to be very big. It is really
difficult to fit the gear of this size when the overall width of the shredder is fixed to be
300mm.

Figure 5: Gear Drive Design-2

3 Gears MOTOR
Input rpm 750 rpm
Input Power 2(pi)NT/60 3 kW High Power
4.02306 HP
Input Torque 38.21656 Nm
PCD of Gear 1 0.03 m
Force on Gear 1 2547.771 N

Gear Ratio 3.53 Fixed


RPM on Gear 2 212.4646
PCD of Gear 2 0.1059 m
Torque on Gear 2 134.9045 Nm

Gear Ratio_2 3.53 Fixed


Meeting
RPM on Gear 3 60.18827
Criteria
PCD of Gear 3 0.373827 m Very Big Gear
Meeting
Torque on Gear 3 476.2127 Nm
Criteria

Radius of Cutter 0.0375 m


Force on Cutter 3597.452 N
Table 2: Gear Drive Calculations-2

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The major drawback in the OPTION 2 was that the size of the Gear 3 was around
370mm, more than the size of the overall design of shredder. So, Not Feasible!!
Thus, for the Gear Drive, option-1 was finalized and was included in the design.

3.2. Gear Design


After finalizing the gear drive, the stage comes to design the gears themselves for the
shredder. The design process of the gears is standard that uses the pitch circle diameter
(PCD) and the number of teeth as the design inputs and gives out the dimensions for the
design. For calculating the design parameters of the gears, an excel sheet was prepared as
3 gears were required to create the final design.
1. Gear 1: The gear that is connected to the electric motor and drives the complete
shredder.
2. Gear 2: This is connected to the 1st drive shaft on which the cutters are also
mounted. On the other side it is driven by the gear 1 that transmits the torque at
defined rpm.
3. Gear 3: This gear is mounted on the other side of the drive; it connects the 2 drive
shafts and transmits the power from the 1st shaft to the 2nd shaft.

The detailed design sheets along with the PCD and number of teeth are explained below:

3.2.1. Gear 1
The position of this gear in the design is also shown in the below figure.

Figure 6: Gear 1 Position and Design

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The calculation sheet for the 1st gear is shown as below.

Input
Pressure angle, Pa = 14.5 or 20 20 deg.
Diametral pitch, Pd = N/D 0.2 -
Number of gear teeth, N = - 12 -
Gear hub diameter = - 20.00 mm
Gear hub width = - 25.00 mm
Bore diameter = - 1.875 mm

Calculation
Pitch circle diameter, D = N / Pd 60.000 mm
Addendum, A = 1 / Pd 5.000 mm
Dedendum, B = 1.157 / Pd 5.785 mm
Whole depth= Addendum+Dedendum, d = 2.157 / Pd 10.785 mm
Clearance, C = .157 / Pd 0.785 mm
Outside
diameter, OD = D + (2*A) 70.000 mm
or OD = (N + 2) / Pd 70.000 mm
Root
circle diameter, RD = D - (2*B) 48.430 mm
or RD = (N - 2.314) / Pd 48.430 mm
Base circle, BC = D*Cos(Pa*.01745) 56.362 mm
Circular
pitch, CP = π*D / N 15.708 mm
or CP = π / Pd 15.708 mm
Chordal thickness, TC = D*Sin(90*.01745/N) 5.000 mm
Chordal addendum, AC = A + N^2 / (4*D) 5.600 mm
Working depth, WD = 2*A 10.000 mm
Note: Excel requires degrees to be converted to radians. Degrees x .01745 = Radians
π= 3.1416

Table 3: Gear Design Sheet-1

The basic dimensions calculated from the above calculations are shown in the drawing
below.

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Figure 7: Gear-1 Drawing

3.2.2. Gear 2
The calculation sheet for the 2nd gear is shown as below.

Input
Pressure angle, Pa = 14.5 or 20 20 deg.
Diametral pitch, Pd = N/D 0.173 -
Number of gear teeth, N = - 36 -
Gear hub diameter = - 20.00 mm
Gear hub width = - 25.00 mm
Bore diameter = - 1.875 mm

Calculation
Pitch circle diameter, D = N / Pd 208.092 mm
Addendum, A = 1 / Pd 5.780 mm
Dedendum, B = 1.157 / Pd 6.688 mm
Whole depth= Addendum+Dedendum, d = 2.157 / Pd 12.468 mm
Clearance, C = .157 / Pd 0.908 mm
Outside
diameter, OD = D + (2*A) 219.653 mm
or OD = (N + 2) / Pd 219.653 mm

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Root
circle diameter, RD = D - (2*B) 194.717 mm
or RD = (N - 2.314) / Pd 194.717 mm
Base circle, BC = D*Cos(Pa*.01745) 195.476 mm
Circular
pitch, CP = π*D / N 18.160 mm
or CP = π / Pd 18.160 mm
Chordal thickness, TC = D*Sin(90*.01745/N) 5.780 mm
Chordal addendum, AC = A + N^2 / (4*D) 7.337 mm
Working depth, WD = 2*A 11.561 mm
Note: Excel requires degrees to be converted to radians. Degrees x .01745 = Radians
π= 3.1416

Table 4: Gear Design Sheet-2

The position of this gear in the design is also shown in the figure below:

Figure 8: Gear 2 Position and Design

The basic dimensions calculated from the above calculations are shown in the drawing
below.

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Figure 9: Gear-2 Drawing

3.2.3. Gear 3
The calculation sheet for the 3rd gear is shown as below.

Spur Gear Dimensions


Input
Pressure angle, Pa = 14.5 or 20 20 deg.
Diametral pitch, Pd = N/D 0.2857 -
Number of gear teeth, N = - 20 -
Gear hub diameter = - 20.00 mm
Gear hub width = - 25.00 mm
Bore diameter = - 1.875 mm

Calculation
Pitch circle diameter, D = N / Pd 70.004 mm
Addendum, A = 1 / Pd 3.500 mm
Dedendum, B = 1.157 / Pd 4.050 mm
Whole depth= Addendum+Dedendum, d = 2.157 / Pd 7.550 mm
Clearance, C = .157 / Pd 0.550 mm
Outside
diameter, OD = D + (2*A) 77.004 mm
or OD = (N + 2) / Pd 77.004 mm

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Root circle
diameter, RD = D - (2*B) 61.904 mm
or RD = (N - 2.314) / Pd 61.904 mm
Base circle, BC = D*Cos(Pa*.01745) 65.759 mm
Circular pitch, CP
= π*D / N 10.996 mm
or CP = π / Pd 10.996 mm
Chordal thickness, TC = D*Sin(90*.01745/N) 3.500 mm
Chordal addendum, AC = A + N^2 / (4*D) 4.929 mm
Working depth, WD = 2*A 7.000 mm
Note: Excel requires degrees to be converted to radians. Degrees x .01745 = Radians
π= 3.1416

Table 5: Gear Design Sheet-3

The position of this gear in the design is also shown in the figure below. 2 same gears are
used in the whole assembly as shown.

Figure 10: Gear 3 Position and Design

The basic dimensions calculated from the above calculations are shown in the drawing
below.

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Figure 11: Gear-3 Drawing

3.3. Body Design

The shredder body is shown in the figure below. The assembly is placed on the table for
representation; it can also be fixed on the floor, as per the requirements.

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Figure 12: Shredder Body Design

Figure 13: Shredder Components a) Hopper (Top Left) b) Drive Shaft (Top Right) c)
Gear Cover (Bottom Left) d) Motor Cover (Bottom Right)

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Figure 14: Shredder Dimensions

The overall dimensions of the Shredder are 300mmX450mmX335mm. The height of the
shredder can be reduced to 300mm to meet the design specification requirements if
required.

3.4. Cutter Design

The design details of the cutter are shown as below.


 As per the requirements, the size of the cutting chip should be 5mmX5mm. Hence
the width of the cutter is kept as 5mm.
 The material of the cutter is selected as HSS (High Speed Steel). It is the standard
for the cutting tools.
 Since the force acting on the cutting tip is high, the case hardening is also required
at the tip.

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Figure 15: Cutter Design

Figure 16: Cutter Drawing

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3.5. Cutter Assembly
All the components described above are assembled together to form assembly as shown
below. The cutter assembly is the most important that should be assembled with
perfection on the shaft. The clearance of 2mm is also kept in the assembly for the fittings.
 Cutters are stacked together to form assembly.
 The guide vanes are assembled to guide the raw material onto the cutter for
cutting.
 These also act as the feeder on to the cutter.

Figure 17: Cutter Assembly

3.6. Safety Features


The design is created operator friendly keeping all the safety precautions as shown below.
 All the moving components are covered with the cover as shown below.
 The vents are opened in the cover for heat dissipation and visual inspections.

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 The assembly is mounted on a table to provide comfort to the operator
considering the Ergonomic Design Factor.

Figure 18: Safety Features

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CHAPTER IV: FEM SIMULATION

The FEM Simulation is carried out on the Shredder Assembly to understand the strength
perspective of the design using ANSYS Software. The durability factor of the Shredder is
important to predict the fatigue life.
The stress values on the supporting structure and the cutter blades are important to
understand its strength and the areas of improvements before production and design
finalization. The Modal Analysis is done to check the resonance of the structure with the
drive motor.
The details of the simulation are shown below.

4.1. Geometry for FEM Simulation

The geometry considered for the simulation is shown in the figure below.

Figure 19: FEM Geometry

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4.2. FEA Modeling Details

Motor, gears and coupling gears were removed for the model simplification. The cutter
assembly, Guide blades were modeled as 3D tetrahedron second order elements
(tetrahedron 10). The Covers and the Motor Casing were modeled using Hex dominant
mesh (Shell 4Nodes).

Figure 20: FEM Model Details

4.3. Load Cases


The extreme case for the Cutter is the choking at the cutting edge at the maximum torque
of the motor. This is simulated at 3 different locations as shown in the figure. The
maximum moment is applied on the shaft as was calculated in the Drive Calculations.

Figure 21: Position of Cutters for Load Cases

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Load Cases Moment (Nm) Choking Location

Choking in center 472.25 Center

Choking Left 472.25 Left

Choking Right 472.25 Right

Table 6: Load Cases for Cutter Choking

4.4. Boundary Conditions

Since the Shredder will be placed on some flat surface, either of table or ground, the base
of the assembly is considered as fixed for the calculations.

Figure 22: Boundary Conditions

4.5. Simulation Results

The calculations are performed based on the above model, loads and boundary
conditions, the calculation results are shown below based on the type of simulations
done.

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4.5.1. Modal Analysis

Ideally, the modal analysis shows the first frequency is the natural frequency, if the
model has all degrees of freedom constrained.

But in our model, the results of the Modal Simulation shows that the first two frequencies
are near to Zero this is because the cutters are free two rotate. The cutters are free to
rotate along the shaft axis and also the gears are free to rotate about their axes. Also it can
be seen that there is no unconnected part in the assembly.

Figure 23: Results of Modal Analysis

4.5.2. Choking on Left Cutter

These results show that if the cutter gets choked on the left side due to the excessive
loading or may be due to some foreign particle. This choking will happen at the
maximum torque, thus, this case is extreme for the cutter.

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Figure 24: Results of Choking on Left Cutter

4.5.3. Choking on Center Cutter

Figure 25: Results of Choking on Center Cutter

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4.5.4. Choking on Right Cutter

Figure 26: Results of Choking on Right Cutter

4.6. Discussion of Simulation Results

By looking at the above results, it can be inferred that.


 It can be seen from the above results that the shaft on which the cutter blades are
welded is critical and needs improvement as the stress values are near to the
Ultimate Yield Point of the material [750N/mm2].
 It should also be considered that the load case simulated is extreme and the
probability of occurrence is low.
 It is recommended to use solid shaft in place of a hollow tube.
 Since the dimensions on the Cutter Blades cannot be changed, the case hardening
is required on the cutting edges to strengthen them for the extreme load case.
 It is also recommended to use pillar blocks to mount the shaft in the design.

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CHAPTER V: CONCLUSION

From the above design report, it can be concluded that the design created for the shredder
is as per the specifications provided. The overall dimensions, power inputs, gear ratio etc
are as per the requirements.
 The functionality of the shredder also seems good as per the Engineering
knowledge gained so far and can be checked after making the prototype.
 The safety features are also included for safe and prolong working of the machine.
 The design is manufacturing friendly using general equipments available in the
Mechanical Workshop and easily available material.
 The selection of the motor for the drive is also standard but may be cost high as it
is the low rpm motor.
 The FEM is also carried out on the whole assembly to check the strength and
durability of the machine and was found that with small changes as mentioned in
recommendations.
This design project work gave a thorough insight of the designing and simulating a
complete working mechanical system. The knowledge of CAD and CAE together can do
a lot of innovation for the society.

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REFERENCES

1. SolidWorks manual document.


2. ANSYS help file.
3. Design document provided by the college professor as the design introduction and
design specifications.
4. Dudley’s Handbook of Practical Gear Design and Manufacturing (Third Edition)
by S. P. Radzevich.
5. Wiley’s Gear and Gear Drives book by Damir T. Jelaska.

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