Epicicloidal 2 estagios

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DESIGN OF A TWO STAGE EPICYCLIC GEARBOX
IN SINTERED METAL GEARS

A Thesis by
Shirish Vatkar
Master of Science
Wichita State University, 2007
Bachelor of Engineering, University of Pune, India 1998

Submitted to the Department of Mechanical Engineering
and the faculty of the Graduate S chool of
Wichita State University
in partial fulfillment of
the requirements for the degree ofMaster of Science

MAY 2007

DESIGN OF A TWO STAGE EPICYCLIC GEARBOX
IN SINTERED METAL GEARS

I have examined the final copy of this thesis for form and
content and recommend that it be accepted in partial fulfillment
of the requirement for the degree of Master of Science in
Mechanical Engineering.

________________________________________
Dr. George Talia, Committee Chair

We haveread this thesis
and recommend its acceptance

________________________________________
Dr. Benham Behr, Committee Member

________________________________________
Dr. Gamal Weheba, Committee Member

ii

ACKNOWLEDGEMENTS

This

Thesis

is

by

far

the

most

significant

scientific

accomplishment in my life and it would be impossible without
people

whosupported

me

and

believed

in

me.

Most of all I would like to thank my research advisor,
Professor George Talia. He is not only a great advisor with in
depth knowledge but also and most importantly a kind person. His
trust in me all through my Masters has brought me to this day
when

I

stand

tall

with

confidence.

My special thanks to Dr. Benham Behr and Dr. GamalWeheba
for being a part of this journey in my education.

iii

ABSTRACT
The
epicyclic

goal
spur

of

this

gearbox

thesis
for

was

to

sintering

research

and

manufacturing

develop
process.

Sintered type of manufacturing process has been in place for
quite

a

knowledge

long
in

time,
the

though

material,

its

usage

has

beenprocesses

and

design

limited
of

by

these

parameters integrated together for optimization. The pages to
follow provide information on Sintering process and the design
of gear parts.
The focus has been to investigate different type of sinter
materials and design a 2- stage gearbox with high efficiency.
Other aim is also to showcase the advantage of using methods ofmanufacturing that save cost and provide a reliable product.

iv

PREFACE
This report is the result of our master’s thesis project.
Gears have been driving components in mechanical industry and
several machinery successes can be levied upon the advancement
in

design

of

conventionally

gears.
known

Gear
to

design

be

a

and

manufacturing

machining

operation.

isWith

advancement in sintering process gears can be manufactured to a
greater degree of accuracy and at costs that save tremendous.
Though a few sectors like automobiles etc use this production
method for manufacturing of gears but the vital part is the
design

convenience

and

production

consistency

that

is

still

unknown to most of the industrial manufacturer. Thepreceding
work

brings

information

and

advantages

of

using

Sintering

process for gears.
Miniature gearboxes have been used in various materials like
plastics

in

Application

several
of

machines

gearboxes

like

in

printers,

epicyclic

type

copiers
and

etc.

miniature

structure is a difficult design work when machining is involved.
Thesame when encompassed with Sintered manufacturing process
makes design easier and less time consuming.
The papers to follow provide a vivid method of designing
and manufacturing gearboxes in sintered metal at prices that are
astonishing.

v

TABLE OF CONTENTS

Chapter
1

Introduction…………………………………………………………………………………………………………………………1
1.1
1.2
1.3

2

2.2
2.3
2.4

2.5...
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