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ANALYSIS and IMPROV of En 353 STEEL USI ALYSIS AND IJMTES | International Journal of Modern Trends in Engineering and Science ISSN: 2348 -3121 ANALYSIS AND IMPROVING THE HARDNESS OF En 353 STEEL USING CRYOGENIC TREATMENT K.Sriharrish¹, M.Karthikeyan 2 1 M.E. (Manufacturing Engineering) Student , 2Assistant Professor Department of Mechanical Engineering, Karpagam University, Coimbatore, India. 2 E-mail a ddresses : [email protected] , [email protected] ___________________________________________________________________________ Abstract - Gears are used to transmit large amount of power in mechanical transmission system with compact layout. For this high loading they mostly prefer worm wheel because of its high torque capacity and strength. In this teeth fracture occurs due to the effect on metal of repeated cycle of stress called fatigue and due to improper hardness. Due to this improper hardness, fatig ue occurs in the teeth end and hence it develops due to continuous heavy loading. Hence to rectify this, our investigation consists of visual examination, chemical composition analysis, hardness analysis, stress analysis, finite element analysis & cryogenic treatme nt on steel. The chemical design analysis results the gear is manufactured by En353. The hardness analysis shows the failure occur due to improper heat treatment. Cryogenic treatment is to increase the hardness of material. Hence I concluded by this proje ct that we can reduce the fracture of teeth by providing the cryogenic treatment to it and to increasing the hardness of teeth. Keywords – Cryogenic treatment; Gear failure; En353 Steel; ___________________________________________________________________________ 1. INTRODUCTION investigation and careful fractographic study on the This project describes the detailed study on failed gear shaft , the carburized layer & the core zone the failed gear. The possible failure reasons are were conducted [3]. analyzed. Planetary gearing system is a system that consists of three planet gears. Typically the planet gears are mounted on a carrier which itself may rotate relative to sun gear. The planetary gearing system may also incorporate the use of an outer ring gear, which meshes the planet gears. The material used for the manufacture of gears depends on the strength and service like wear noise etc. The steel is used for high strength gears and steel may be plain carbon steel or alloy steel. The steel gears are usually heat treated in order to combine properly the toughness and tooth material. In general, the steels selected for gear applications must satisfy the basic two requirements for ease of fabrication and processing. Fig. 1. Structure of Two Stage Planet Gear Several researchers studied on the failures of the elements of power transmission system a s there The possible failure reasons were assessed. A are many cases of the failures [1]. A failure pinion which has a part of an air motor driving on a investigation has been conducted on a diesel -engine diesel generator (DG) of a power plants emergency gear-shaft used in truck which is made of EN353 steel power supply system, was found to be failed into three [2] . He describes the detailed metallurgical parts during a routine checkup of a dc. Volume: 01 Issue: 05 May 2014 www.ijmtes.com 1 A systematic failure analysis was carried out Gears to find out the reasons for this unexpected fracture of A gear is a rotating machine part having the pinion during operation. The result indicates that cut teeth, or cogs, which mesh with another toothed the fracture was caused by fatigue with a fatigue crack part in order to transmit torque. Two or more gears initiating from the fillet of one of the pinion teeth. working in tandem are called a transmission and can Due to misalignment that was present the pinion did produce a mechanical advantage through a gear not mesh proper with the ring gear during start up ratio and thus may be considered a simple machine. operation and this lead to a high stress concentration Geared de vices can change the speed, torque, and at the root of the pinion. Typical applications of En direction of a power source . The most common 353 steel is being heavy duty gears, shaft, pinions, situation is for a gear to mesh with another gear, camshaft, & gudgeon pins. however a gear can also mesh a non -rotating toothed The power transmission input is 22kw at part, called a rack, thereby 1440rpm and the final output power is 18rpm. For producing translation instead of rotation. such huge reduction of three stage planetary gearbox is used. The gear reduction can be achieved by using The gears in a transmission are analogous to the gear ratio (1+R/S). The kind of gearing is the wheels in a pulley . An advantage of gears is that occasionally used in tractors foundry division and the teeth of a gear prevent slipping. When two gears construction equipments to give the high torque to the of unequal number of teeth are co mbined a driving wheels. mechanical advantage is produced, with both the rotational speeds and the torques of the two gears 2. METHODOLOGY differing in a simple relationship. Failure analysis is the route of gathering and In transmissions which offer multiple gear investigating statistics to conclude the cause of failure ratios, such as bicycles and cars, the term gear, as and how to avoid it from recurring. It is a significant in first gear , refers to a gear ratio rather than an actual control in manufacturing industry, where it is a very physical gear. The term is used to describe similar important tool used in the development of new devices even when gear ratio is continuous rather products and for the upgrading of existing products. than discrete , or when the device does not actually En353 STEEL En353 STEEL contain any gears, as in a continuously variable transmission. B. Types External Vs Internal Gears HARDNESS CRYOGENIC TREATMEN T An external gear is one with the teeth formed on the outer surface of a cylinder or cone. Conversely, FEM HARDNESS an internal gear is one with the teeth formed on the ANALYSIS inner surface of a cylinder or cone. For bevel gears, an internal gear is one with the pitch angle exceeding 90 FEM degrees. Internal gears do not cause direction reversal. ANALYSIS COMPARISON RESULT & CONCLUSION Fig. 3. External gear vs Internal gear Fig. 2. Flow Chart of Methodology C. Spur Gear A. Properties of en353 steel Volume: 01 Issue: 05 May 2014 www.ijmtes.com 2 Spur gears or straight-cut gears are the Double helical gears, or herringbone gears, simplest type of gear. They consist of a cylinder or overcome the problem of axial thrust presented by disk with the teeth projecting radially, and although "single" helical gears, by having two sets of teeth that they are not straight-sided in form, the edge of each are set in a V shape. A double helical gear can be tooth is straight and aligned parallel to the axis of thought of as two mirrored helical gears joined rotation. These gears can be meshed together correctly together. This arrangement c ancels out the net axial only if they are fitted to parallel shafts. thrust, since each half of the gear thrusts in the opposite direction. Double helical gears are more difficult to manufacture due to their more complicated shape. Fig. 4. Spur gear D. Helical Helical or "dry fixed" gears offer a refinement over spur gears. The leading edges of the teeth are not parallel to the axis of rotation, but are set at an angle. Since the gear is curved, this angling causes the tooth shape to be a segment of a helix. Helical gears can be meshed in a parallel or crossed orientations. T he former refers to Fig. 6. Double Helical Gear when the shafts are parallel to each other; this is the most common orientation. In the latter, the shafts are F. Worm Gear non-parallel, and in this configuration are sometimes Worm-and-gear sets are a simple and known as "skew gears". compact way to achieve a high torque, low speed gear A disadvantage of helical gears is a ratio. For example, helical gears are normally limited resultant thrust along the axis of the gear, which needs to gear ratios of less than 10:1 while worm -and-gear to be accommodated by appropriate thrust bearings, sets vary from 10:1 to 500:1. A disadvantage is the and a greater degree of sliding friction between the potenti al for considerable sliding action, leading to meshing teeth, often addressed with additives in the low efficiency. lubricant Worm gears can be considered a species of helical gear, but its helix angle is usually somewhat large (close to 90 degrees) and its body is usually fairly long in the axial direction; and it is these attributes which give it screw like qualities. The distinction between a worm and a helical gear is made when at least one tooth persists for a full rotation around the helix. If this occurs, it is a 'worm'; if not, it is a 'helical gear'. A worm may have as few as one tooth. If that tooth persists for several turns around the helix, the worm will appear, superficially, to have more than one tooth, but what one in fact sees is the same tooth reappearing at intervals along the length of Fig. 5. Helical Gears the worm. T he usual screw nomenclature applies: a one-toothed worm is called single thread or single E. Double Helical start ; a worm with more than one tooth is called Volume: 01 Issue: 05 May 2014 www.ijmtes.com 3 multiple thread or multiple start. The helix angle of a H. Gear Nomenclature worm is not usually specified. Instead, the lead angle, which is equal to 90 degrees minus the helix angle, is given.
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