DESIGN AND MANUFACTURING OF A TWO-STAGE REDUCTION GEARBOX WITH 3D PRINTERS

Year 2023, Volume: 7 Issue: 1, 18 - 28, 29.04.2023

Serpil Karakuş

https://doi.org/10.46519/ij3dptdi.1206809

Cited By: 2

Abstract

ABSTRACT
3D printers, which have been used in recent years, enable the conversion of a digital model into a physical 3D object by placing the filament material layer by layer and can help a wide variety of industries. Digital models can be created using software such as Solidworks and Catia or data created by a 3D scanner.
This study designed all parts of a two-stage reducer gearbox consisting of spur and helical gear pairs. The torques are calculated according to the input power. Shafts that can transmit torques are designed.
On the other hand, gear wheels were calculated according to the total reduction ratio and were designed to transmit torques. CAD software (Solidworks) designed the gearbox parts, assembled them, and simulated them. Thus a digital model has been created. CAD models were transferred to the 3D printer. The slicing was done precisely using Cura software,
On the other hand, the Marlin software reads the G codes created with Cura software sent from the computer. PLA (Polylactic Acid) was used as the filament material. The manufactured gearbox worked adequately, and the number of revolutions was reduced to 40 rpm from 800 rpm.

Keywords: Gearbox, Gears, 3D printing, CAD, Additive manufacturing

Keywords

Gearbox, Gears, 3D printing, CAD, Additive manufacturing

References

• 1. Kaygusuz, B., Özerinç, S., “3 Boyutlu Yazıcı ile Üretilen PLA Bazlı Yapıların Mekanik özelliklerinin İncelenmesi”, Makine Tasarım ve İmalat dergisi, Vol.16, Issue 1, Pages 1-6, 2018.
• 2. Prabhu, R., Devaraju, A., “Failure analysis and restructuring model of transfer feeder gearbox in thermal powerplant”, Materials Today: Proceedings, Vol. 39, Pages 633–638, 2021.
• 3. Haghbin, N., Bone, D., Young, K., ‘Controlled extrusion-based 3D printing of micro-channels with the geometric modelling of deposited roads”, Journal of Manufacturing Processes, Vol. 67, Pages 406-417, 2021.
• 4. Elmrabet, N., Sieges, P., “Dimensional onsiderations on the mechanical properties of 3D printed polymer parts”, Polymer Testing, Vol. 90, Issue 106656, 2020.
• 5. Kishore, S.N., Reddy, A.V.V., Rao, L.B., “Design and optimization of spur gears in a single-stage reduction gearbox”, Materials Today: Proceedings Article in Press, 2022.
• 6. Jadhav, A., Jadhav, V.S., “A review on 3Dprinting: An additive manufacturing technology”, Materials Today: Proceedings, Article in press, 2022.
• 7. Mikolajczyk, T., Malinowski, T., Moldowan, L., Fuven, H., “CAD-CAM system for manufacturing innovative hybrid design using 3D printing”, Procedia Manufacturing, Vol. 32, Pages 22-28, 2019.
• 8. Ranjan, R., Kumar, D., Kundu, M., Moi, S.C., “A critical review on Classification of materials used in 3D printing Process”, Materials Today: Proceedings”, Vol. 61, Pages 43-49. 2022.
• 9. Kumar, D., Manohar, G.A., Teja, R.S., “The state of art 3D printing: A case study of Ganesh Idol”, Materials Today: Proceedings, Vol. 56, Pages 455-461, 2022.
• 10. Junk, S., Kuen, C., “Review of Open Source and Freeware CAD Systems for Use with 3D-Printing”, 26th CIRP Design Conference, Pages 430-435, 2016.
• 11. Haghbin,N., Bone, D., Young, K., “Controlled extrusion-based 3D printing of micro-channels with the geometric modelling of deposited roads”, Journal of Manufacturing Processes”, Vol. 67, Pages 406-417, 2021.
• 12. Rais, M.H., Li, Y., Ahmed, I., “Dynamic-thermal and localized filament-kinetic attacks on fused filament fabrication based 3D printing process”, Additive Manufacturing, Vol. 46, Issue 102200, 2021.
• 13. Sharma, A., Rai, A., “Fused deposition modelling (FDM) based 3D & 4D Printing: A state of art review”, Materials Today: Proceedings, Article in press, 2022.
• 14. ISO 6336-5, Calculation of spur and helical gears load capacity, 2016.
• 15. Solidworks Software 2020-2021.
• 16. Shigley, J.E., Mischke, C.R., Budynas, R.G., "Mechanical Engineering Design", 7th edition, McGraw-Hill publishers, 2004.
• 17. https://3detay.com/cura-egitimi-cura-3d-dilimleme /
• 18. Maden H., Kamber Ö.Ş., Kamber B.R. “QVAC Halı Yıkama Makinesinin Üst Kapak Tasarımı Geliştirilmesi ve Prototip Üretimi”, Int. J. of 3D Printing Tech. Dig. Ind., 5(2): 109-119, 2021.
• 19. Karaçor M., Delioğlu B., Şahin C. “3b Baskı Teknolojisi Kullanılarak Otonom Sualtı Aracı Tasarımı Ve Prototip Üretimi”, Int. J. of 3D Printing Tech. Dig. Ind., 5(3): 663-675, 2021.
• 20. Özaslan H., Bozdemir M., “Alev Gizleyen Tasarımı ve Prototip İmalatı”, Int. J. of 3D Printing Tech. Dig. Ind., 6(1): 176-185, 2022.
• 21. Bozca, M., Fietkau, P., “Empirical model based optimization of gearbox geometric design parameters to reduce rattle noise in an automotive transmission”, Mechanism and Machine Theory Vol. 45, Pages 1599-1612, 2010.
• 22. Bozca, M., “Transmission error model-based optimisation of the geometric design parameters of an automotive transmission gearbox to reduce gear-rattle noise”, Applied Acoustics Vol. 130, Pages 247-259, 2018.
• 23. Raia, P., Agrawala, A., Sainia, M.L., Jodderb, C., Gopal Barman, A., “Volume optimization of helical gear with profile shift using real coded genetic algorithm”, Procedia Computer Science Vol. 133, Pages 718-724, 2018.
• 24. Miler, D., Hoi, M., “Optimization of cylindrical gear pairs: A review”, Mechanism and Machine Theory, Vol. 156, Issue 104156, 2021.
• 25. Younes, E.B., Changenet, C., Bruyere, J., Rigaud, E., Liaudet, J.P., “Multi-objective optimization of gear unit design to improve efficiency and transmission error”, Mechanism and Machine Theory, Vol. 167, Issue 104499, 2022.
• 26. Choi, C., Ahn, H., Park, Y.J., Lee, G.H., Kim, S.C., “Influence of gear tooth addendum and dedendum on the helical gear optimization considering mass, efficiency, and transmission error”, Mechanism and Machine Theory, Vol. 166, Issue 104476, 2021.
• 27. Jabbour, T., Asmar, G., “Tooth stress calculation of metal spur and helical gears”, Mechanism and Machine Theory, Vol. 92, Pages 375–390, 2015.
• 28. Kim, S.C., Moon, S.G., Sohn, J.H., Park, Y.J., Choi, C.H., Lee, G.H., ”Macro geometry optimization of a helical gear pair for mass, efficiency, and transmission error”, Mechanism and Machine Theory, Vol. 144, Issue 103634, 2020.
• 29. Zhang, J., Fard, M., ”Effects of helix angle, mechanical errors, and coefficient of friction on the time-varying tooth-root stress of helical gears”, Measurement, Vol. 118, Pages 135–146, 2018. 30. Roach, D.J., Hamel, C.M., Dunn, C.K., Johnson, M.V., Kuang, X., Qi, H.J., “The m4 3D printer: A multi-material multi-method additive manufacturing platform for future 3D printed structures”, Additive Manufacturing, Vol. 29, Issue 100819, 2019.
• 31. Veteška, P., Hajdúchováa, Z., Feranc, J., Tomanováa, K., Milde, J., Kritikos, M., Ľ ubošBa ˇca, Janek, M., “Novel composite filament usable in low-cost 3D printers for fabrication of complex ceramic shapes”, Applied Materials Today Vol. 22, Issue 100949, 2021.
• 32. Bozca, M., “Optimisation of Effective Design Parameters for an Automotive Transmission Gearbox to Reduce Tooth Bending Stress”, Modern Mechanical Engineering, Vol. 7, Pages 35-56, 2017.
• 33. www.yr.com.tr