This document summarizes a student group's mini manufacturing project to design and build a gear box assembly. It describes the objectives of gaining experience with lab machines and manufacturing processes. It lists the group members and project title. It then explains the components of the gear box, the machines used in the manufacturing processes, and calculations for the gear dimensions and speed ratios. The assembly, testing and results are outlined, showing how different output speeds can be achieved by engaging different gears.

1. In the NAME OF ALLAH, the
Most Beneficent, Most Merciful
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2. Manufacturing process lab
ME-304L
•Mini project
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3. Group members
Fawad
Irfanullah
khan
Nauman Shehryar
khan ishaque
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4. Project title
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5. Overview of the presentation
• Objectives
• Introduction
• Components of the assembly
• Machine used and operations performed
• Calculations
• Results and conclusions
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6. Objectives
• To hand over experience of the machines
present in the lab.
• To apply the theory of manufacturing
process and other subjects.
• To be aware of the various manufacturing
processes.
• To get greater torque and smaller speed.
• To get smaller torque and greater speed.
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7. Introduction
Gear box
Combination of gears, to produce low or
high speed output.
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8. Components of the assembly
(gear box)
Following are the components of gear box.
• Spur gears
• Shafts
• Bearings
• Wooden square boxes
• Square housing of wood
• Handle
• Outer casing of wood
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10. Machines used
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11. Process
involved
• Casting:-
4 discs of Aluminum of different dimensions
and also of two shafts.
• Facing:-
Facing of all the discs and shafts by lathe
machine.
• Turning:-
Turning of the shafts and discs by lathe machine.
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12. Continued……..
• Drilling:-
In order to fix the disc on the shaft, holes were
required which were drilled using a drill machine.
• Boring:-
For enlarging the diameter of the discs we carried
out boring, to ensure a tight fit of discs and shafts.
• Milling:-
Milling machine was used for making teeth on the
discs(gear teeth….)
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13. Continued……
• Tapping
Done for making internal threads in collars.
• Cutting
Cutting of bolts was also done.
• Filing
filing was done for adjusting the shaft dia
to the bearing.
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14. Calculation carried out
As a result of finishing the diameter of the
discs was brought to
• Disc 1: 104 mm
• Disc 2: 88 mm
• Disc 3: 62 mm
• Disc 4: 46 mm
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15. Calculation for number of teeth
Formula used for calculating number of teeth
N=(D/m)-2
m= module =2
Disc 1: N=50
Disc 2: N=42
Disc 3: N=29
Disc 4: N=21
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16. Cutter used
• Cutter # 4,5,5,6 are used for disc 1,2,3,4
respectively having module ratio same i.e. 2.
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17. Preparation of outer casing and
supports
• Making of wooden box for the motion of shaft and
bearing.
• Making of flat square housing for inserting the
bearings so that the bearing becomes tight.
• Making of outer casing from wood, one base and two
stands
• Making of holes and a slot in stands to support
shafts.
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18. Assembling
• We mount discs 1,3 and 4 on shaft A by
bolts.
• The other disc # 2 mount on 2nd shaft B.
• Insert all the bearing in the correct holes.
• Shaft B is the input shaft and shaft A is
output shaft.
• Gear 2 will mesh with gears 1,3 and 4 and
giving the respective speed ratio.
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19. Assembly
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20. Formula used for calculating the
speed ratio
• Mv=no of teeth on driver gear /no of teeth on
driven gear
also
Mv=nout/ninput
Where n= speed (rpm)
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21. Calculation for outputs
• When gear 2 mesh with gear 1,
for one rotation of shaft B, shaft A
rotates 0.84 times.
• When gear 2 mesh with gear 3,
for one rotation of shaft B, shaft A
rotates 1.44 times.
• When gear 2mesh with gear 4,
for one rotation of shaft B, shaft A
rotates 2 times. 21

22. procedure
• The bearings are inserted in shaft B and
then bearings are also inserted into the flat
wooden plates where it becomes tight.
• The flat wooden plates can move forward
and backward in the boxes for changing the
gears.
• The boxes used here to support the bearings
in each side.
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23. Procedure(contd)
• The slot in the stands is used for the left and
rightward motion of the shaft B for meshing
with the other gears
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24. Results and conclusion
• The results we obtain from this project are.
• We can get three different speeds at output
shaft by just changing the meshing of input
gear with the output gears.
• The overall result we get from this mini
project is that it is very necessary for a
Mechanical Engineer to have hand on
experience on these various types of
machines.
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25. Practical applications…
• Automobiles
• Most machines
• (lathe machine etc)
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26. Any Question…
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