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DEVELOPMENT OF LIGHT
WEIGHT COMPOSITE GEARSFOR AUTOMOBILE
PRESENTED BY
JAGADISHKUMAR K
KOUSHIK S V
SIBI VISHVAK S
ANBARASAN C M
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Automobile industries, the major contributor to worlds
economy have been continually putting efforts to reduce
the weight of the automobile.
An automobile is a combination of many subsystems and
each and every subsystem contributes to the weight of an
automobile.
The choice of a gear material depends on four factors:
o Mechanical properties
o Metallurgical characteristics
o lan! preparation
o Manufacturing process
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Aluminium
" most environmental friendly
" material of choice" weighs one"third of steel
A comparison between high alloy steel #$ %&% and aluminium '('&
PROPERTIES STEEL EN 353 ALUMINIUM 7075
)ensity *!g+ -%(( -/(
0o"efficient of Thermal
e1pansion *
2.34 %.54
6oungs modulus*78a /2% '/.'
Tensile strength *M8a 3-2.& &'
PROPERTIES STEEL EN 353 ALUMINIUM 7075
-%(( -/(
2.34 %.54
6oungs modulus*78a /2% '/.'
Tensile strength *M8a 3-2.& &'
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89;#M )#uirements.
Major draw bac! is its weight.
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?#0T=@#
)evelop an alternate material for transmissiongears.
9educing weight.
To test the gears for re>uired tor>uetransmission and power.
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M#T);76
PROBLEMDEFINITION
LITERATURESURVEY
FEASIBILITYSTUDY
DESIGN
CALCULATION
CNTPRODUCTION
CNTCHARACTERISATI
ON
GEARFABRICATION
GEAR TESTING
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)#B=7$ < B8C9 7#A9Maruti Suzuki Alto 800 specifcation
PARAMETER VALUES
Maximum Power 4 !"#
Maximum Tor$ue %& Nm
Fir'( Gear )i* +,-
Se.o/0 Gear )i* 1,23
T"ir0 Gear)i* 2,++
Four(" Gear)i* &,&
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i D 7ear ratio E " eli1 angle
D #ngine Tor>ue D Ma1imum tor>ue
D #ngine speed D $umber of teeth on pinionD Module " $umber of teeth on gear
a D 0entre distance # D #>uivalent 6oungs modulus
D
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ending strengthm 62,13
m m 7 2,11Pre8erre0 mo0u9e m 7 +
CHECKING OF BENDING STRENGTH
7 :
7
7 2+3 ; -%1
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0ontact strengtha G *iH/
a G *.53 4
a G 3/.' mm
CHECKING OF CONTACT STENGTH
7 :
7 :
7 31,+ ; 3+&
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7ear dimensions
!AAMETES "A#$EMo%ule +Centre %istance 3 mm
Hei&'t (actor 2Toot' %ept' &,%- mm
!itc' %ia)eter
*!inion+ 224 mm
!itc' %ia)eter
*Gear+% mm
Tip %ia)eter
*!inion+21& mm
Tip %ia)eter
*Gear+4 mm
oot %ia)eter
*!inion+2&3,- mm
oot %ia)eter
*Gear+ %&,- mm
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0arbon nano tubes
" (u!e
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Hexa>o/a9 '"ee( o8 >ra#"e/e mo0e9 o8 )a* a/arm."air /a/o (u!e
)!* a i> /a/o(u!e a/0 ).* a ."ira9/a/o (u!e
arm."air )/ /* ."ira9 8or )/ m* i>a> 8or )/ &*
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#lectrodes
Cath!" #$% && ' (00 &&
A)!" I3 mm J (( mm
.a("o0e a/o0e
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8roduction of 0$T
8reparation of electrode
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8ressure set"up
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loc! diagram of )0 arc discharge method
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Trials
TRIALS CATALYST VOLTAGE*V+
PRESSU
RE*,-./&
+
WEIGHT*-+
$
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9T#M 0haracteriation
0arbon coated cathode grip 9T#M ?#; ?#M /((
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Trial"/CATALYST F"1N2*005 -+
VOLTAGE 2( @
PRESSURE "(.% !g+cmN
9T#M image and electro diffraction pattern of trial"/
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Trial"CATALYST F"
VOLTAGE 2( @
PRESSURE "(.5 !g+cmN
HRTEM ima>e a/0 E9e.(ro 0ira.(io/ #a((er/ o8 (ria9
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Trial"%CATALYST F"44/")"
VOLTAGE 2( @
PRESSURE "(.& !g+cmN
HRTEM ima>e a/0 E9e.(ro/ 0ira.(io/ #a((er/ o8 (ria9
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7ravity casting
*a 7ear
*b die component*c furnace
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B>ueee casting
*a 7ear with bro!en die
*b accurate gear profile
*c hydraulic press
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obbing process
*a Melting of Al"'('& pieces
*b 0$T powder
*c 7ear blan!s
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*a 7ear of (. O of 0$T
*b 7ear of (.%O of 0$T
*c Pear test pieces
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7ear testing
S,
N
O
MATEIA# -IAGONA
#
*))+
-IAGONA
#
*))+
#OA- .!/
*K&(+
H"N
A9
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Bcanning #lectron Microscopy *B#M
B#M image of Al"0$T gear
0onfirmation of 0$T presence in the matri1
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Pear test
Pi/ o/ 0i'. wear (e'(er
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0omparison of samples
S2!2)-
!26ta)/"
*&+
H"2-ht
66*&+
H"2-ht
66*&+
H"2-ht
66*&+
(. g (.% g (.& g
Beries / Beries Beries %
(00 /2 /& /
800 & /- /5
%00 %' 2
900 5% %& -
$000 5& 5( %%
$(00 5' 5 %-
$800 &% 5' 5%
$%00 &' & 5-$900 3 &' &/
(000 3- 3/ &3
((00 ' 3& 3(
(800 '' '( 33
(%00 -5 '3 '(
(900 -2 - '5
3000 23 -2 '2
& -&& 2&&& 2-&& 1&&& 1-&& +&&& +-&&&
1&
4&
3&
&
2&&
21&
"ei>"( 9o'')m*
S9i0i/> 0i'(a/.e )m*
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9esults
PROCES
SBEFORE HARDENING AFTER HARDENING
CNT *-+ (. (.% (. (.%
HVN ( 5% '
CNT *-+ 0( 03 05
WEAR RATE
*&.&2)+&.'#"% /.5#"% /5.#"%
CNT *-+ 0( 03 05
&.'#"% /.5#"% /5.#"%
ardness comparison
Pear rate comparison
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Tha), :;
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