This document summarizes a mini project report on a gear/bearing puller created using rapid prototyping. The report discusses rapid prototyping techniques like fused deposition modeling used to 3D print the puller. It then describes the purpose of a bearing puller to remove stuck parts from shafts, and details the design of the printed puller including individual parts and assembled views. The report concludes with information on the project team and references used.
1. A Mini Project Report
On
GEAR / BEARING PULLER
PRESENTED WITH LOVE :
• BHAGYARAJ V - 1BM19IM002
• DHRUVITH M - 1BM10IM007
• GAURAV C - 1BM19IM011
• RIDHA MEHTA - 1BM19IM
In the partial fulfillment for
III Semester Miniproject (19IM3DCMP1)
on
RAPID PROTOTYPING
Under The Guidance Of
Smt. Prof. SHYLAJA .V
Department of Industrial Engineering and Management
B.M.S. College of Engineering, Bengaluru – 560 019
2020-21
2. RAPID PROTOTYPING - - -
Rapid prototyping (RP) is the fabrication of prototype parts
directly from a computer solid model without the need for
an expensive tool or die set.
Rapid prototyping (RP) is the fabrication of prototype parts
directly from a computer solid model without the need for
an expensive tool or die set.
Where the design closely matches the proposed finished
product it is said to be a high fidelity prototype, as
opposed to a low fidelity prototype, where there is a
marked difference between the prototype and the final product.
3. Rapid prototyping (RP) includes a variety of manufacturing
technologies, although most utilise layered additive
manufacturing. However, other technologies used for RP include
high-speed machining, casting, moulding and extruding.
While additive manufacturing is the most common
rapid prototyping process, other more conventional
processes can also be used to create prototypes.
4. Process include :
• Subtractive - whereby a block of material is
carved to produce the desired shape using
milling, grinding or turning.
• Compressive - whereby a semi-solid or liquid
material is forced into the desired shape before
being solidified, such as with casting,
compressive sintering or moulding.
5. Different Types of Rapid Prototyping :
Stereolithography (SLA) or Vat Photopolymerization -
This fast and affordable technique was the first successful method of commercial 3D
printing. It uses a bath of photosensitive liquid which is solidified layer-by-layer using a
computer-controlled ultra violet (UV) light.
Selective Laser Sintering (SLS) -
Used for both metal and plastic prototyping, SLS uses a powder bed to build a
prototype one layer at a time using a laser to heat and sinter the powdered
material. However, the strength of the parts is not as good as with SLA, while
the surface of the finished product is usually rough and may require secondary
work to finish it.
6. Fused Deposition Modelling (FDM) or Material Jetting -
This inexpensive, easy-to-use process can be found in most non-industrial desktop 3D
printers. It uses a spool of thermoplastic filament which is melted inside a printing
nozzle barrel before the resulting liquid plastic is laid down layer-by-layer according
to a computer deposition program.
Selective Laser Melting (SLM) or Powder Bed Fusion -
Often known as powder bed fusion, this process is favoured for making high-strength,
complex parts. Selective Laser Melting is frequently used by the aerospace,
automotive, defence and medical industries.
7. Laminated Object Manufacturing (LOM) or Sheet Lamination -
This inexpensive process is less sophisticated than SLM or SLS, but it does not require
specially controlled conditions. LOM builds up a series of thin laminates that have
been accurately cut with laser beams or another cutting device to create the CAD
pattern design.
Digital Light Processing (DLP) -
Similar to SLA, this technique also uses the polymerisation of resins which are cured
using a more conventional light source than with SLA. While faster and cheaper than
SLA, DLP often requires the use of support structures and post-build curing.
8. Binder Jetting -
This technique allows for one or many parts to be printed at one time,
although the parts produced are not as strong as those created using SLS.
Binder Jetting uses a powder bed onto which nozzles spray micro-fine
droplets of a liquid to bond the powder particles together to form a layer of
the part.
9. Rapid Prototyping Method Used For This Project
FDM : (Fused Deposition Modeling)
• Fused Deposition Modeling (FDM), or Fused Filament
Fabrication (FFF), is an additive manufacturing process that
belongs to the material extrusion family.
• In FDM, an object is built by selectively depositing melted
material in a pre-determined path layer-by-layer.
• The materials used are thermoplastic polymers and come in
a filament form.
10. FDM fabrication process working
• A spool of thermoplastic filament is first loaded into the
printer
• Once the nozzle has reached the desired temperature, the
filament is fed to the extrusion head and in the nozzle
where it melts.
• The extrusion head is attached to a 3-axis system that
allows it to move in the X, Y and Z directions.
• The melted material is extruded in thin strands and is
deposited layer-by-layer in predetermined locations, where
it cools and solidifies.
• Sometimes the cooling of the material is accelerated
through the use of cooling fans attached on the extrusion
head.
11. • To fill an area, multiple passes are required
(similar to coloring a rectangle with a marker).
• When a layer is finished, the build platform
moves down (or in other machine setups, the
extrusion head moves up) and a new layer is
deposited.
• This process is repeated until the part is
complete.
12. THE PARAMETERS ARE:
• Pressure: 448kPa
• Temperature: 190-240 degrees centigrade
• Filament Thickness: 1.75 mm(PLA)
• Surface Finish: Rough
• Build Speed: Low
• Material used: ABS, Poly Lactic Acid, Elastomers
• Nozzle Size: 0.4mm
• Speed in the 1st layer is 40-50mm/s, 80-100mm/s in the
second layer and the fastest is 150mm/s
13. • Product designers use this process for rapid manufacturing of representative
prototype parts. This can aid visualisation, design and development of the
manufacturing process ahead of mass production.
• Originally, rapid prototyping was used to create parts and scale models for
the automotive industry although it has since been taken up by a wide range
applications, across multiple industries such as medical and aerospace.
• Rapid tooling is another application of RP, whereby a part, such as an injection
mould plug or ultrasound sensor wedge, is made and used as a tool in another
process.
Applications
14. • Rapid Prototyping is a very cost effective way to
prototype products as it is an automated process,
requiring less staff to operate.
• This process is also extremely precise, being able to
use computer aided design (CAD) to help reduce the
amount of material wastage and does not require
special tools for prototyping each new product.
• Being able to act quickly and solve ay problems also
reduces the risk of costly errors during the
manufacturing stage.
Advantages of Rapid Prototype :-
16. Bearing Pullers
Bearing pullers are used to remove
parts such as bearings, gears or
pulleys from a shaft.
They have legs which circle around
the back or inside of a part, and a
forcing screw which centres up
against the end of the shaft.
17. As the forcing screw is tightened, the arms pull
the part towards the end of the shaft.
A bearing puller is used to remove bearings,
gears or pulleys, which are components that
are in almost constant use. Because of this,
they become worn or even damaged and need
to be replaced.
18. • A bearing is a part of a machine (such as an
engine) that compels relative motion. Put simply,
this means that a bearing rotates at the same
speed as the rotating component; this helps to
reduce friction between the moving parts.
BEARING
• A gear is a wheel containing teeth that work with
others to alter the relation between the speed of a
driving mechanism (such as the engine of a
vehicle) and the speed of the driven parts (the
wheels).
GEAR
19. This is a two legged bearing puller
removing a pulley from a shaft.
28. Why do we need a puller ?
If a part, such as a gear, bearing or ball bearing,
is so tight that you cannot loosen it with your
own strength, you need a tool to help you do so.
In a situation where a stuck part is installed on
a machine, for example, leading to a standstill,
disassembly must be fast as well as efficient,
safe and gentle.
Only a puller can give you that.
29. Pulling with an external puller is the most common
type of application and is required when –
the part to be pulled off is freely gripped and removed
from the outside.
A classic external puller consists of a crossbar through
which a spindle runs and to which either two or three
arms are attached.
When pulling, the arms of the external puller grip the
part to be pulled off from the outside.
By tightening the spindle, the part to be pulled off is
released from the shaft.
External puller
33. (any questions ?)
• Bhagyaraj V
• Dhruvith M
• Gaurav C
• Ridha Mehta
Quick revise :
• Rapid prototyping
• Fused deposition model
• Bearing puller
Definition
Uses
3d & 2d drawing
Applications
Printed model
• Reference
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