IJSART - Volume 1 Issue 4 –APRIL 2015
ISSN [ONLINE]: 2395-1052
Modified Gear De-Burring Machine Using Kinematic
Four-Bar Linkage Mechanism
1
2
Ajay Sutar , Suhas Patil , Nilesh Langade 3, Dipak Kute 4
Department of Mechanical Engineering
1, 2,3,4
D.Y.Patil College Of Engg,Ambi,Pune,India.
Abstract- Today’s Industrial field is very developed .Every day
new concepts, new ideas are emerging out with their
relevance to industry. New technologies are helping to
increase efficiency with less consumption of power. Now days,
at the age of automation many of industries are having variety
of machines, satisfying the condition available at their best. So
accordingly the birth of low cost gear deburring machine took
place from high cost, complicated gear deburring machine.
become more likely. Radiusing eliminates edge defects,
minimizes stress risers and contribute to better mesh and lower
operating noise between individual components in a
drivetrain. In summary, removing burrs and sharp edges
improves the quality, efficiency, performance and reliability of
power transmission components.
Keywords- Gear deburring, efficiency,low cost.
The KEM Deburring Machine as shown in fig.1. has
been developed in WERA technical center. Fig.2 shows
working of actual gear deburring machine in industry. It has
been designed for deburring and chamfering special and bevel
gears.The machine concept is used for short serials and a wide
variety of work parts. The tool features have five degrees of
liberty and is able to perform any work part profile with
extreme precision and speed. It also suitable for other complex
work part shapes requiring precise and sharp chamfering.
I. INTRODUCTION
For small scale gear manufacturing industries after
manufacturing the gear, deburring of the gear is required for
that high costly machines are used. For such small scale units
it is not economical to spend more money and space on these
types of machines, so there is a need of developing a small
unit which consumes less cost and compact. So we design a
deburring machine which fulfills this type of requirement of
small scale gear manufacturing industries. In our project we
focused on deburring of gears of module 1.5 ,2,2.5 ,3 module
with different number of teeth by using simple four bar
kinematic linkage instead of automatic indexer. We eliminate
the various sensors and other auxiliaries parts which are used
in the existing industrial gear deburring machine. Here we
used gear (work-piece) holding fixture arrangement ( mandrel
& chuck), gear indexing mechanism using kinematic four-bar
linkage mechanism with uni-directional clutch arrangement
facility to be provided for multi-module indexing to
accommodate different sizes of spur gear.
KEM 502 deburring machine ©FIMAT:
Fig.1
II. LITERATURE REVIEW
Weiler.[1]Author studied on brushes required for
gear demurring They said that all cutting and shaping
operations produce some type of burr or leave a sharp edge.
On power transmission components such as gears, these
undesirable by-products are especially troublesome. Even
well-attached, heavy burrs can loosen from the parent edge,
either during assembly or in actual operation. These chips are
then free to travel through the power transmission system and
damage components. Under operating conditions, sharp edges
become areas where internal stresses concentrate and failures
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Fig.2
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IJSART - Volume 1 Issue 4 –APRIL 2015
ISSN [ONLINE]: 2395-1052
Why chamfer and deburr ?
The reasons for choosing a controlled , high-quality of
chamfering and deburring process are:
• To avoid breakage excessive carburizing along the tooth
edges can often cause breakage when the gear is running.
• To avoid damaging gears and bearings – If burrs are not
removed, they may chip off during the running cycle and
cause damage to the other gears and bearings.
• To avoid poor tool life in the following finishing
processes (see next slide) – Hardened burrs will cause
shorter tool life in the following finishing processes The
build-up of material along the profile due to chamfering
must be straightened in a subsequent rolling cycle.
• Removal of sharp burrs reduces the risk of tool handling
injuries.
In figure (3) are shown two gears , first before the
chamfering and deburring operation and the second after these
operation. Figure (4)shows a gear with a big burr. Basically
there are different types of chamfer: in only one or in both
flanks, with a constant size along the profile , with /without
chamfer in root diameter.
Grinding wheel selection
Selection of grinding wheel is based on the following
parameters.
• Type of abrasive
• Grain size.
• Type of bond.
• Structure of wheel.
• Grade.
III. METHODOLOGY
Design consists of application of scientific
principles, technical data and imagination for development of
new or improvised machine or mechanism to perform a
specific function with maximum economy and efficiency. In
our project to design a special purpose machine we have
adopted a very very careful approach. Our total design work
has been divided into two parts.
System design:
Fig.3
It mainly concerns the various physical constraints
and ergonomics, arrangement of various components on main
frame at system, space requirements, man plus machine
interactions. It also concerns weight of machine from ground
level, total hight of machine and a lot more.
Mechanical design:
This phase is very important from the view of
designer .Many preliminary alternatives are eliminated during
this phase. Designer should have sound knowledge of physical
properties of material, deformation, loads stresses and failure
of material. They know about theories of failure and wear
analysis. Mechanical design divides into two types.
• Design parts
In this detail design is done and dimensions thus
obtained are compared to next highest dimension which are
readily available in market this simplifies the assembly as well
as post production servicing work.
Fig.4
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IJSART - Volume 1 Issue 4 –APRIL 2015
• Parts to be purchased
The various tolerances on work pieces are specified
in the production drawings. The process charts are prepared
and passed on to the manufacturing stage .The parts are to be
purchased directly are specified &selected from standard
catalogues.
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belt, pulley, proximity sensors, , inching switches so machine
become compact also cost is reduced.
IV. IMPLEMENTATION
Four Bar Mechanism:
Actual design:
In order to understand this machine we have the following
block diagram
Fig.6 Nomenclature of four bar mechanism
Fig.5 Block diagram of gear deburring machine by
using four bar kinematic
mechanism
In existing gear deburring machine auto indexer is
used for the purpose of indexing of gear for deburring. It
consist various types of proximity sensors, inching switches,
variable ac/dc motor, pulley, belts so cost of machine and
maintenance cost is high. Existing machine which used is
fully automatic for safety purpose covering of machine sound
proofing is required so this type of machine is economically
deployed in large scale production. But concerning in small or
medium scale production unit it is not so much economical .In
attempt to that we design a new deburring machine with slight
modification. Instead of auto indexer for the purpose of
indexing the gear for deburring , simple four bar kinematic
chain mechanism which is pneumatically operated with
unidirectional clutch is used. We eliminate other parts like
Page | 146
A four bar mechanism consists of four rigid link
which are linked in the form of quadrilateral by four pin joints.
A link that makes complete revolution is called crank, the link
opposite to the fixed link is the coupler and forth link is a lever
or rocker if oscillates or another crank if rotates. Here r1, r2,
r3, r4 are the links of mechanisms.
Grashoff’s Law:
For a planar four bar type linkage, the sum of the
shortest and longest links cannot be greater than the sum of
remaining links if there is continuous relative motion between
two members.
Crank-Rocker Mechanism:
It is inversion of four bar mechanism which is used
here.In a four bar linkage, if the shorter side link revolves and
the other rocks (i.e., oscillates), it is called a crank and rocker
mechanism. In this case, there is only a small change, it leaves
the smallest side and connect at any of its adjacent side as the
frame. Then (in figure) the smallest side „s‟ will have full 360
degree revolution while the other link adjacent to the frame
has only oscillating motion (link p). This kind of mechanism is
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IJSART - Volume 1 Issue 4 –APRIL 2015
ISSN [ONLINE]: 2395-1052
hence called a crank-lever mechanism or a crank-rocker
mechanism or a rotary-oscillating
V. RESULTS
After implementation four bar mechanism following results
are obtained.
Fig.7 crank-lever mechanism
Unidirectional clutch:
VI. CONCLUSION
This machine is suitable for agriculture machinery
manufacturing, molded gear industry, timer pulley
manufacturing and sprocket and chain wheel manufacturing
.etc. Gears of module 1.5 ,2,3 module with different number of
teeth can be deburred easily and visual inspection should be
possible to evaluate the effective removal of burr.
ACKNOWLEDGMENT
Fig.8.Unidirectional clutch
Unidirectional clutch allows to transmit power in
only either direction as shown in fig.8. In other direction it is
locked similar to sprocket wheel of cycle. This clutch is used
here which help in indexing of gear. During the forward stroke
of pneumatic cylinder clutch rotates clockwise direction
indexing of gear done. During the return stroke it is not rotates
that time deburring of gear takes place by brush and grinding
wheel. So this combine indexing and deburring minimizes
time.
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Every orientation works has an impart of many
people and it becomes the duty of author to express deep
gratitude for the same. We express our special thanks
&gratitude to Prof. P.K. Zaware sir for their full support
guidance & cooperation in our project.
We also thankful to our Hod and staff of mechanical
department for assistance and providing necessary help.
REFERENCES
[1]
Weiler. “Gear deburring with power brushes info.
Broacher” , form reorder no.: wc357 rev. 5-14 •
5142lp Weiler corporation , 2014
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IJSART - Volume 1 Issue 4 –APRIL 2015
[2]
Mike Magee. “Deburring, Defined” , Gear solutions
,page no 19-23, January 2005
[3]
Shuo-jen lee ,Chung ping liu, Tienjung fan and Yi-ho
chen., “Deburring Miniature Components by
Electrochemical Method”,
int. J. Electrochem.
Sci.,1713 – 1721 , 1 February 2013
[4]
c. Kobialka, Gleason--pfauter, “Contemporary gear
pre -machining solutions”, AGMA technical paper,
October 2012
[5]
Dr. Oliver Winkel , “New Developments in Gear
Hobbing”., Gear
Technology page.no 45-52 ,
March/April 2010
[6]
Ali Alallak., “Deburring of components a survey of
current and future deburring processes”, kth |
kungligatekniskahögskolan , September 2010
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