Great Deal! Get Instant $10 FREE in Account on First Order + 10% Cashback on Every Order Order Now

Description: You will work in a group project to disassemble a product (a gearbox), identify the material of each component, reason why this material was chosen and how it was manufactured, sketch the...

1 answer below »
Description: You will work in a group project to disassemble a product (a gearbox), identify the material of each component, reason why this material was chosen and how it was manufactured, sketch the components and produce drawings. Weight: 30% Due dates: Individual Drawings Week 6 (5%) and Group Report Week 12 (25%) Location: The workshop room for this project is O-134. As this is a flexible learning space where you will be undertaking a practical, you are required to wear clothed in shoes and present your safety induction sticker. Group Formation: You will form groups on QUT Blackboard under the folder Project > Group Formation. There will be 5 students per group, maximum. You will form yourselves into groups by the end of Thursday the 9th of March Week 2, as the workshop needs the group lists before the workshops in Week 3. You will form groups with people in the same gearbox workshop as yourself, as you will work together in the workshop to disassemble and assemble the gearbox in weeks 3 and week 11. Note that on Blackboard, you will therefo
Document Preview:

EGB214 Gearbox Project EGB214 GEARBOX PROJECT 1. Key Information Project coordinator: Daniel Stoker: XXXXXXXXXX Description: You will work in a group project to disassemble a product (a gearbox), identify the material of each component, reason why this material was chosen and how it was manufactured, sketch the components and produce drawings. Weight: 30% Due dates: Individual Drawings Week 6 (5%) and Group Report Week 12 (25%) Location: The workshop room for this project is O-134. As this is a flexible learning space where you will be undertaking a practical, you are required to wear clothed in shoes and present your safety induction sticker. Group Formation: You will form groups on QUT Blackboard under the folder Project > Group Formation. There will be 5 students per group, maximum. You will form yourselves into groups by the th end of Thursday the 9 of March Week 2, as the workshop needs the group lists before the workshops in Week 3. You will form groups with people in the same gearbox workshop as yourself, as you will work together in the workshop to disassemble and assemble the gearbox in weeks 3 and week 11. Note that on Blackboard, you will therefore only be able to join groups from the session you are enrolled in on QUT Virtual through class registration. It is highly recommended you meet people during the lecture and form groups from there. Be aware that during the end of your session, there will be another 80 students about to enter. If you do not need to be in the Garden Lounge (outside the practical room), please leave the area. Gearbox components: As a part of this project, you will be issued gearbox components during your workshop session. You will disassemble the gearbox in the workshop, and take the components with you for further analysis. A team leader will be required to sign their name to the components and it will be their responsibility to return the components at the completion...

Answered Same Day Dec 26, 2021

Solution

David answered on Dec 26 2021
122 Votes
Manufacturing Processes
Major components of VF30 Gea
ox -
 Bearings - input shaft non-drive end bearing
o input shaft drive end bearing
o Output bearing
o output shaft bearing
 Input shaft
 Output shaft
 Housing footing
 Housing
Manufacturing of Bearing –
Inner and outer ring manufacturing -
Ball bearing is used with rotating shafts. They are generally made of high ca
on steel such as AISI
52100. The hardness of steel is achieved by a heat treatment process which increase the hardness up
60-64 Rockwell c hardness scale.
Chemical composition
Raw material
Raw material used for making bearing. Outer and inner ring
Are forged rings. forge material is used for better strength
And mechanical properties. Secondary for some bearings
Casted rings are used for cost reduction and other factors
But most of the time forged ring are the prime choice.
Turning operation
The turning operation is divided into various
Operations, viz O.D face & Bore.
These operations are mostly done on lathe for
Small rings.
Heat Treatment
After machining process is done, heat treatment follows to change its micro structure from
austenite to martensite. This is done by heating the rings to austenitc region and then
suddenly oil quenched. The sudden change in temperature leads to formation of martinsite,
Element C Si Mn S P CR
Min 0.98 0.15 0.25 - - 1.30
max 1.10 0.35 0.45 0.025 0.025 1.60
Comment [PS1]: Possible source:
http:
www.freepatentsonline.com/y2015/03
08495.html
Comment [PS2]: Possible sources:
http:
documents.mx/documents/gear-
finishing-methodpptx.html
https:
www.scribd.com/doc/122104336/gea
-finishing-method-pptx
Comment [PS3]: Possible source:
http:
www.freepatentsonline.com/y2015/03
08495.html
http:
www.plagscan.com/highlight?doc=114082899&source=22&cite=0&url=http%3A%2F%2Fwww.freepatentsonline.com%2Fy2015%2F0308495.html#jump
http:
www.plagscan.com/highlight?doc=114082899&source=22&cite=0&url=http%3A%2F%2Fwww.freepatentsonline.com%2Fy2015%2F0308495.html#jump
http:
www.plagscan.com/highlight?doc=114082899&source=22&cite=0&url=http%3A%2F%2Fwww.freepatentsonline.com%2Fy2015%2F0308495.html#jump
http:
www.plagscan.com/highlight?doc=114082899&source=13&cite=1&url=http%3A%2F%2Fdocuments.mx%2Fdocuments%2Fgear-finishing-methodpptx.html#jump
http:
www.plagscan.com/highlight?doc=114082899&source=13&cite=1&url=http%3A%2F%2Fdocuments.mx%2Fdocuments%2Fgear-finishing-methodpptx.html#jump
http:
www.plagscan.com/highlight?doc=114082899&source=13&cite=1&url=http%3A%2F%2Fdocuments.mx%2Fdocuments%2Fgear-finishing-methodpptx.html#jump
http:
www.plagscan.com/highlight?doc=114082899&source=15&cite=1&url=https%3A%2F%2Fwww.scribd.com%2Fdoc%2F122104336%2Fgear-finishing-method-pptx#jump
http:
www.plagscan.com/highlight?doc=114082899&source=15&cite=1&url=https%3A%2F%2Fwww.scribd.com%2Fdoc%2F122104336%2Fgear-finishing-method-pptx#jump
http:
www.plagscan.com/highlight?doc=114082899&source=15&cite=1&url=https%3A%2F%2Fwww.scribd.com%2Fdoc%2F122104336%2Fgear-finishing-method-pptx#jump
http:
www.plagscan.com/highlight?doc=114082899&source=22&cite=1&url=http%3A%2F%2Fwww.freepatentsonline.com%2Fy2015%2F0308495.html#jump
http:
www.plagscan.com/highlight?doc=114082899&source=22&cite=1&url=http%3A%2F%2Fwww.freepatentsonline.com%2Fy2015%2F0308495.html#jump
http:
www.plagscan.com/highlight?doc=114082899&source=22&cite=1&url=http%3A%2F%2Fwww.freepatentsonline.com%2Fy2015%2F0308495.html#jump
which is very strong and harden steel. As quench media oil is used since it has very high
oiling point and oil controls the cooling rate too.
Grinding section
To achieve the required dimensions, grinding is done on all the faces. This operation is
mostly done by automatic process control, so that great accuracy can be achieved. The
operation incudes -
1. Rough O.D. grinding on centre less grinder
2. Face grinding on rotary table grinder
3. Bore grinding
4. External track grinding
5. Internal track grinding
6. Finish O.D. grinding
Manufacturing of steel balls, Cage and Final Assembly
STEEL BALLS CAGE
Comment [PS4]: Possible source:
http:
www.google.com/patents/US3853638
Comment [PS5]: Possible sources:
http:
chemistry.wlu.edu/WebPDF-
allaccess/111 Problem
Sets/assignments/PZero-2001.pdf
http:
www.google.com/patents/US3853638
http:
www.plagscan.com/highlight?doc=114082899&source=24&cite=1&url=http%3A%2F%2Fwww.google.com%2Fpatents%2FUS3853638#jump
http:
www.plagscan.com/highlight?doc=114082899&source=24&cite=1&url=http%3A%2F%2Fwww.google.com%2Fpatents%2FUS3853638#jump
http:
www.plagscan.com/highlight?doc=114082899&source=23&cite=0&url=http%3A%2F%2Fchemistry.wlu.edu%2FWebPDF-allaccess%2F111%2520Problem%2520Sets%2Fassignments%2FPZero-2001.pdf#jump
http:
www.plagscan.com/highlight?doc=114082899&source=23&cite=0&url=http%3A%2F%2Fchemistry.wlu.edu%2FWebPDF-allaccess%2F111%2520Problem%2520Sets%2Fassignments%2FPZero-2001.pdf#jump
http:
www.plagscan.com/highlight?doc=114082899&source=23&cite=0&url=http%3A%2F%2Fchemistry.wlu.edu%2FWebPDF-allaccess%2F111%2520Problem%2520Sets%2Fassignments%2FPZero-2001.pdf#jump
http:
www.plagscan.com/highlight?doc=114082899&source=23&cite=0&url=http%3A%2F%2Fchemistry.wlu.edu%2FWebPDF-allaccess%2F111%2520Problem%2520Sets%2Fassignments%2FPZero-2001.pdf#jump
http:
www.plagscan.com/highlight?doc=114082899&source=24&cite=0&url=http%3A%2F%2Fwww.google.com%2Fpatents%2FUS3853638#jump
http:
www.plagscan.com/highlight?doc=114082899&source=24&cite=0&url=http%3A%2F%2Fwww.google.com%2Fpatents%2FUS3853638#jump
Finally, balls, ring and cage are assembled together.
Advantage & Disadvantages
ï‚· Chances of waviness on ring is very less as compare to castings.
ï‚· Cost efficient.
ï‚· Less time consuming & reduce scrape material
ï‚· Initial cost is high
Manufacturing of input and output shaft with Gear
Hollow shafts and steps are mainly manufactured from semi-products by means of
machining. These semi products are mainly obtained in metal forming processes (e.g.
extrusion, forging and rolling). By means of metal forming methods toothed wheel rims can
e also effectively manufactured. There are two most important methods of metal forming of
teeth and they are forging and rolling. By combining together metal forming processes of
shaft and teeth production of input shaft can take place. In order to do this, the cross-wedge
olling method (CWR) is used.
Worm gear
The axis of worm and worm gear intersect below 90° in most of the cases, provided that there
is a sufficiently high clearance between the axes. During the operation vi
ations are
abso
ed to a high degree. Noise generation during the operation is low. However, because of
the high friction, the degree of efficiency get reduced. This type of gear is usually employed
in combination with a globoid gear with cylindrical worm, which is made of steel to avoid
tempering and grinding.
These are the materials generally used for making gears -
Fe
ous metals – for high loads
• Grey cast iron – It is prefe
ed for reasonable strength and wear resistance. Ease of casting
and machining, low cost etc. are also some other factors.
• Forged high ca
on steels and alloy steels (Ni-Cr, Mo etc.) which are either fully hardened
or surface hardened for use under high stresses and speed.
Manufacture of gears –
This needs several processing and operations in the following sequential stages -
⎯ Preforming the blank with or without teeth.
⎯ Annealing of the blank (if required) as in case of forged or cast steels.
Comment [PS6]: Possible sources:
http:
www.nmbtc.com/pdf/company/csr_re
port_ball_bearings_pursuing_precision_limits.
pdf
http:
www.minebeamitsumi.com/english/co
p/environment/special/2012/1187903_7019.h
tml
Comment [PS7]: Possible sources:
http:
imim.pl/files/archiwum/Vol3_2009/7.p
df
http:
www.sciencedirect.com/science/article
pii/S1526612516300159
Comment [PS8]: Possible sources:
http:
imim.pl/files/archiwum/Vol3_2009/7.p
df
http:
www.nmbtc.com/pdf/company/csr_re
port_ball_bearings_pursuing_precision_limits.
pdf
http:
www.minebeamitsumi.com/english/co
p/environment/special/2012/1187903_7019.h
tml
Comment [PS9]: Possible source:
http:
imim.pl/files/archiwum/Vol3_2009/7.p
df
Comment [PS10]: Possible sources:
http:
www.bearing.co.il
ochure1.pdf
http:
www.nskamericas.com/cps
de/xbc
n
a_en/Gea
ox.pdf
http:
www.nskamericas.com/cps
de/dt
na
_en/literature_bearing/Gea
ox.pdf
Comment [PS11]: Possible sources:
http:
www.nskamericas.com/cps
de/dt
na
_en/literature_bearing/Gea
ox.pdf
http:
www.nskamericas.com/cps
de/xbc
n
a_en/Gea
ox.pdf
Comment [PS12]: Possible sources:
http:
www.nskamericas.com/cps
de/dt
na
_en/literature_bearing/Gea
ox.pdf
http:
www.nskamericas.com/cps
de/xbc
n
a_en/Gea
ox.pdf
Comment [PS13]: Possible sources:
http:
www.nptel.ac.in/courses/112105127/p
df/LM-32.pdf
http:
documents.mx/documents/32-screw-
threads-and-gear-manufacturing-
methods.html
http:
docplayer.net/21134613-Module-7-
screw-threads-and-gear-manufacturing-
methods.html ...
Comment [PS14]: Possible sources:
http:
www.nptel.ac.in/courses/112105127/p
df/LM-32.pdf
http:
documents.mx/documents/32-screw-
threads-and-gear-manufacturing- ...
Comment [PS15]: Possible sources:
http:
www.nptel.ac.in/courses/112105127/p
df/LM-32.pdf
http:
documents.mx/documents/32-screw-
threads-and-gear-manufacturing- ...
Comment [PS16]: Possible sources:
http:
www.nptel.ac.in/courses/112105127/p
df/LM-32.pdf
http:
documents.mx/documents/32-screw-
threads-and-gear-manufacturing-...
SOLUTION.PDF

Answer To This Question Is Available To Download

Related Questions & Answers

More Questions »

Submit New Assignment

Copy and Paste Your Assignment Here