MATERIAL OPTIMIZATION OF GEAR AND PINIONFOR PLANETARY GEAR BOX

Guided by Prof. Altamash Ghazi

Mr. Gupta Deepak (11ME24) Mr. Phadatare Kiran (11ME44)

Mr. Shaikh Abrar (11ME50) Mr. Pawale Mustafa (11ME43)

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Prepared by (Group no.08)

ANJUMAN-I-ISLAM’S KALSEKAR TECHNICAL CAMPUS

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Introduction of company:- We got this industrial project from Dynatech Engineering company. The company is located at Taloja , MIDC. They manufacture the following components:-

1. Special Ultra Planetary Gearbox.2. Mixing System.3. Double Cone Vaccum Dryer.4. Tray/Vacuum Tray Dryer.5. Rotary Tunnel Dryer.6. Agitated Pressure / Vaccum Filter.7. Distillation Unit.

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Abstract:-

In Dynatech Engineering co., materials utilized for pinion and gear are EN24 and EN8 respectively. In this company, problem of Gear teeth deformation occurred and They needed to suggest appropriate gear material. We Search for different material optimization methods. We Select weighted point method and confirms it by TOPSIS method and COPRAS method. Analysis is also done by using currently used material and newly suggested material for pinion and gear.

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Problem statement:-

In Dynatech Engineering Co., Gear teeth deformation frequently occurs in planetary gearbox.

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Objective:

To select the appropriate material for Pinion and Gear that would be easily machinable and Hardenable.

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Literature Review:-

Research Paper(1):->TOPSIS is based on the concept of that the chosen alternative should have the shortest geometric distance from the positive ideal solution and longest geometric distance from the negative ideal solution. [10]

Research Paper(2):->COPRAS is based on the concept of listing of all the prospective materials from the best to the worst, taking into account multi conflicting material selection attributes. [5]

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Research Paper(3):->VIKOR ranks alternatives and determines the solution that is the closest to the ideal. [6]

Research Paper(4):->DBA is based on matrix operations which can be easily computed using MATLAB . The DBA method is validated by comparing results of ranking with TOPSIS method. [3]

Research Paper(5):->One of the most suitable model is ELECTRA which uses multiple criteria where all material performance indices and their uncertainties are accounted for simultaneously. [4]

Expected material selection methods Weighted Point MethodTOPSIS Method. COPRAS Method. VIKOR Method. DBA Method. ELECTRA Method.

Selected material selection methods.• Weighted Point Method.• TOPSIS Method.• COPRAS Method.

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Indian standards

BritishStandard

su(N/mm^2)

sy (N/mm^2)

dl(mm)

HB (BHN)

Cost (Rs/kg)

40Ni2Cr1Mo28 EN24 950 600 16 277 80

C45 EN8 710 460 15 229 80

C55MN75 EN9 780 360 15 255 67

35Ni1Cr60 EN111 850 540 18 248 80

30Ni4Cr1 EN30A 1550 1330 8 444 67

40Cr1 EN18 850 540 16 248 -

1)List the essential material properties for the application.

Weighted Point Method

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2) Find GO/NO GO properties and discriminating properties.

GO/NO GO properties.

• Machinability.• Availability.• Hardenability.•Toughness.

Discriminating properties.

•Ultimate tensile stress.•Yield stress.•Elongation.•Hardness.•Cost in Rs.

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Property

1-2

1-3

1-4

1-5

2-3

2-4

2-5

3-4

3-5

4-5

Positive decision(Pi)

Weighting factor W=(Pi/SPi)

1. su 1 1 1 1 4 0.4

2.sy 0 1 0 0 1 0.1

3.dl 0 0 0 1 1 0.1

4.HB 0 1 1 1 3 0.3

5.Cost 0 1 0 0 1 0.1

SPi=10

3) Assign weighting factors ‘W’ to each discriminating properties.

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4) Calculate scale properties ‘B’ for each material.

•In case of properties like ultimate tensile stress, Elongation and hardness.

B = Numerical value of property X 100 Largest value under consideration

•In case of properties like cost.

B = lowest value under consideration X 100 Numerical value of properties

•Calculate material performance index. n r = S Bi x Wi i =1 Where n= Number Of discriminating properties

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Material Selection Chart

Mater-ial

Go/No-Go properties

Su

W1=0.4

Sy

W2=0.1

d l W3=0.1

HBW4=0.3

CostW5=0.1

MaterialPerformanceIndexY=∑BiWi

M A H T B1 B1W1

B2 B2W2

B3 B3W3

B4 B4W4

B5 B5W5

EN24 Y Y Y Y 61.3 24.52 46.1 4.61 88.9 8.89 62.4 18.7 83.7 8.37 65.12

EN8 Y Y Y Y 45.8 18.32 27.7 2.76 83.3 8.33 51.6 15.4 83.7 8.37 53.27

EN9 Y Y Y Y 50.3 20.13 35.3 3.53 83.3 8.33 57.4 17.23

100 10 59.23

EN111 Y Y Y Y 54.8 21.9 41.5 4.15 100 10 55.1 16.7 83.7 8.37 61.23

EN325 Y N Y Y -- -- -- -- -- -- -- -- -- -- --

EN30A

Y Y Y Y 100 40 100 10 44.4 4.44 100 30 100 10 95.4

EN18 Y N Y Y -- -- -- -- -- -- -- -- -- -- --

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Materials TOPSIS COPRAS Weighted Point

EN 24 3 2 2EN 8 4 5 5EN 9 2 4 4EN 111 5 3 3EN 30A 1 1 1

Ranking of materials given by TOPSIS method, COPRAS method and Weighted Point Method.

Comparison of rank of materials by TOPSIS, COPRAS and Weighted Point Method.

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Rank of material

Analysing gear and pinion by using ANSYS software

Input parameters for ANSYS Case 1: EN30A material for pinion and EN 24 material for gear Case 2: EN 24 material for pinion and EN 8 material for gear (currently used materials in

industry) Moment= 100 Nm Module= 8 mm Teeth on pinion= 17 Teeth on gear= 68 Environmental Temperature= 32°C

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Snapshots:

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Equivalent stress of case 1

Equivalent stress of case 2

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Equivalent elastic strain of case 1

Equivalent elastic strain of case 2

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Total deformation of case 1

Total deformation of case 2

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Progress report:-1) Collected information about the composition of material i.e. EN24 and

EN8.2) Short listed the standard gear materials.3) Studied different materials selection methods.4) Selected Weighted Point Method.5) Comparison with TOPSIS method and COPRAS method.6) Analyzing gear and pinion by using currently used material and

suggested material.

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Future Scope In order to reduce maximum total deformation, it requires to apply some other optimization techniques with material optimization, which are as follows.1.DBA method is based on matrix operations which can be easily computed using MATLAB.2.Hardening the gear surface with heat treatment and carburization, that will increase the strength of gear.3.Shot peening can be done to improve surface finish.4.stress can be minimized by introducing stress relief feature at stress zone.

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Conclusion :-

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• By comparing results of Weighted Point Method(WPM), TOPSIS Method & COPRAS Method, it indicates that EN30A material is secured with first priority and EN24 material is secured with second priority.

• ANSYS result indicates that, maximum equivalent stress, maximum equivalent strain and total deformation of case1 is less as compared to case2.

• Hence in case of planetary gear box , EN30A material is suggested for pinion and EN24 material is suggested for gear.

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References:-

[1] PSG Design Data Book compiled by PSG college of Technology, Coimbatore.[2] V.B. Bhandari, Design of machine elements, McGraw-Hill.[3] Rahul Malik, R.K.Garg , S. K.Jarial, “ Optimal selection of gear material by using distance based approach method”, International Journal of Enhanced Research in Science Technology and Engineering, Vol. 3 Issue 8,August-2014, p. 167-176 . [4] Radinko Gligorijevic , Jeremija Jevtic, Djuro Borak, “Material selection in gear design” Faculty of technical science, Novi Sad, May 2008, p. 389-394.[5] Prasenjit Chatterjee, Shankar Chakrabortty, “Gear material selection using complex proportional assessment and additive ratio assessment based approaches: A comparative study” International Journal of material Science and Engineering, Vol.1, No.2, December-2013, p. 104-111. [6] Ali Jahan, K. l. Edward, “VIKOR method for material selection problem with interval numbers and target based criteria”, Material and design, Vol.33, 2013, p.759-765.

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[7]Ashwini Joshi, Vijay Kumar Karma, “Effect on strength of involute spur gear by changing the fillet radius using FEA”, International Journal of Scientific and Engineering Research. Vol.2 Issue 9, September 2011, p.1-5.[8]Y.Sandeep kumar, R.K.Suresh, B.Jayachandraiah, “Optimization of design based on fillet radius and teeth width to minimise the stress on the spur gear with FE Analysis”, IJRTE, Vol.1, Issue 3, August 2012, p. 55-58.[9]Dhavale A.S., Abhay utpat, “Study of stress relief feature at root of teeth of spur gear”, IJERA, Vol.3, Issue 3, June 2013,p. 895-899.[10] Mohammed F. Aly, Hazem A. Attia, Ayman M. Mohammed, “TOPSIS model for best design concept and material selection process”, IJIRSET,Vol.2,Issue 11, November 2013, p.6464-6486.[11] www.Planetarygearbox.org. 

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THANK YOU….