Presentation on designing a Gear box.pptx

Presentation Of a Designing and manufacturing Details of Gear Box

1. Ocean University Of Srilanka B.Sc.Marine Engineering 2019/20 Batch MaE5033 - Machine Design and Project Lecturer – Mr. Kavindu Helshan Group - A

2. Optimizing Plate Rolling Machines with Integrated Gearboxes

3. Table Of Contents 1 6 3 5 2 4

4. Objectives 01. To Design and Develop a Plate Rolling Machine with Integrated Gearbox: Streamline the rolling process by integrating a gearbox enhancing efficiency and precision 02.To Achieve Precise and Consistent Plate Rolling: Ensure uniform thickness and shape across rolled plates, meeting industry standards. 03.To Enhance Operational Efficiency: Reduce energy consumption and manual labor by optimizing the machine's mechanical design. 04.To Improve Machine Durability and Reliability: Utilize high-quality materials and components to extend the machine’s operational life. 05.To Conduct Thorough Testing and Validation: Perform rigorous testing to ensure the machine meets all functional and safety requirements.

5. Problem Description

6. Inefficient Power Usage Traditional machines consume high power even during light-load operations, leading to energy wastage. Operational Limitations Limited speed control and torque management restrict operational flexibility and efficiency. Maintenance and Reliability Concerns Frequent wear and tear result in increased downtime, affecting productivity and reliability . Gearbox Integration Benefits Integrating a gearbox can optimize power usage, provide better torque control, and enhance the overall efficiency and reliability of the plate rolling machine

7. Background Study

8. A thorough review of existing technologies and design principles was conducted Rolling Processes : Analysis of different plate rolling techniques and their limitations. Gearbox Design Research into efficient gearbox designs for high-torque applications. Material Selection Evaluation of suitable materials for the machine's components Finite Element Analysis Simulation of stress and strain to optimize the design.

9. References G.R. Nagpal, "Machine Design," Khanna Publishers. S.K. Duggal, "Mechanical Engineering Design," McGraw-Hill Education Kumar, A., & Singh, P., "Advancements in Plate Rolling Machines with Integrated Gearboxes," Journal of Manufacturing Processes Smith, J., & Brown, T., "Efficiency Enhancement in Metal Forming Processes," International Journal of Mechanical Engineering https://www.machinedesign.com/ https://www.engineering360.com/

10. Design Flow

11. The design process involved several stages to ensure a robust and efficient solution.

12. Conceptual Designs

13. Component Details Material Assumptions & References Loads L1- 8000 Kg L2- 5000 Kg L3- 3000 Kg Cargo Safety factor considered as 2. Hook Swivel hook weight of 31.978 Kg Alloy steel No deflections due to change of loads . No thermal deflections . Wear & tear of the hook is neglected . Connecting sheave is not considered, only a single rope is used HOIST HOOK – The Crosby Group, Inc. (Hook catalogue) Rope = 30 m Diameter = 46mm cross-section area = 1130mm^ 2 Dyform 8PI Stress, lateral & longitudinal strain, thermal deflection , and friction are neglected. Stress concentration throughout the whole rope length is constant . BRIDON.BRKAERT-THE ROPES GROUP Component Details Material Assumptions & References Loads L1- 8000 Kg L2- 5000 Kg L3- 3000 Kg Cargo Safety factor considered as 2. Hook Swivel hook weight of 31.978 Kg Alloy steel No deflections due to change of loads . No thermal deflections . Wear & tear of the hook is neglected . Connecting sheave is not considered, only a single rope is used HOIST HOOK – The Crosby Group, Inc. (Hook catalogue) Rope Dyform 8PI Stress, lateral & longitudinal strain, thermal deflection , and friction are neglected. Stress concentration throughout the whole rope length is constant . BRIDON.BRKAERT-THE ROPES GROUP

14. Motor Power = 29 KW Torque = 6200 Nm Efficiency = 0.864 Rpm = 100 Vibration and friction loss are neglected Three-phase synchronous motors by BAUMULLER Gears ( m = 4 ) ( b = 10m) N1 = 32 , 128 mm N2 = 52 , 208 mm A = 20 , 80 mm B = 64 , 256 mm C = 28 , 112 mm D = 56 , 224 mm E = 38 , 152 mm F = 46 , 184 mm G = 30 , 120 mm H = 22 , 88 mm I = 44 , 176 mm Maraging Steel 1480 Mpa Gear meshing efficiency is 100%. Friction and vibration are neglected A Text Book of Machine Design by J.K. Gupta and R.S. Khurmi

15. Shafts S1 – 40 mm S2 – 45 mm S3 – 25 mm S4 – 40 mm Maraging Steel 2617 Mpa No power reduction. No presence of shock, friction, vibration & thermal stress . Wear of the assembly neglected . Keys N1- 66 mm N2 - 40 mm A - 77 mm C - 60 mm E - 39 mm G - 49 mm H - 39 mm Maraging Steel 2617 Mpa Microstructural deflections were neglected . Thermal defects were neglected . Bearing B1,B2 – NJ208ECM B3 – NU1009ECP B4 – NJ1011ECP B5, B6 – NJ208ECJ B7,B8 – N208ECP 10 Working hours per day. 50 working days per year. 15 working years. Bearing reliability is 0.9 No axial load.

16. Retainer rings N1,B, D,F,I,B1,B2,B5,B6: DSH-40 H,B7,B8: DSH-25 B3: DSH-45 B4: DSH-55 No deflections. Coupling (muff coupling) Input Muff length- 140 mm O/p Dia- 93 mm Key length- 32 mm Width- 14 mm Thickness- 9 mm Output Muff length-140 mm O/p Dia- 93 mm Key length- 130 mm Width- 14 mm Thickness- 9 mm Maraging Steel 2617 Mpa Perfect alignment. Uniform torque distribution. Uniform material properties. No sliding. Casing Length- 730 mm Width- 623 mm Height- 234 mm Aluminum alloy 1060 Environment factors neglected.

17. Final Design Demonstration

18. 3D Modelling and Simulation CAD Design : Detailed 3D models enhance visualization and design accuracy . Design Validation : Ensures robustness and reliability through comprehensive testing. Stress Analysis : Identifies potential failure points under operational loads. Motion Simulations : Assesses dynamic behavior and operational efficiency.

19. Further Enhancements

20. Future-Development will focus on enhancing the machine’s capablities Automation Implementing automated control systems Advanced Materials Utilizing Lighter and more durable materials. Data Analytics Monitoring and analyzing performance data

21. Conclusion

22. The project successfully developed a plate rolling machine with an integrated gearbox . 01 . Efficiency Reduced energy consumption and improved performance. 02. Durability Improved robustness and longer lifespan. 03. Versatility Suitable for various plate thicknesses and materials. 04. Cost-Effectiveness Reduced maintenance costs and increased productivity.

23. Thank You ! Do you have any questions ? M.R.R.AHMATH MES/2019/018 K.BIEWRESH MES/2019/013 J.HAMZA MEM/2019/005