Design and Analysis of Helical Gearbox for Extrusion Process

Abstract

Gearbox system have wide scope in many areas like palm oil, elevator, plastics, steel, chemical, power, sugar, rubber and marine industries. Many researchers have developed and analyze the gearbox to enhance its efficiency. Manufacturing of components of gear box are important to maintain motion and torque transmission capabilities. The development of gearbox casing requires number of considerations like strength, stress, temperature, vibration, etc. The prime objective of present work is to design the gearbox for extrusion process can be used for plastic molding industries. The main objective comprises of structural analysis of gearbox casing and design of bearing housing to minimize the thrust loading on casing generate due to external loading, which use for extrusion process. To achieve the main objective of the present work, a 3D modeling of gearbox done with help of CREO 3.0 software and force analysis is carried out using BEARINX software. Analytical calculation also carried out for validation of force analysis done by BEARINX software. The results obtained using BEARINX are found in agreement with those found analytically. ANSYS software used to carry out structural analysis of casing and results are compared with permissible values. The vibration signal of a gearbox carries the signature of the fault in the gears, and useful for early fault detection of the gearbox. So, it is advisable to carry out vibration analysis and the obtained results can be utilized for further modification if required before it taken for manufacturing. It has not only helped in building cost effective design, but also have helped in reduced prototype development and testing time. To validation of existing work reference gearbox taken for vibration analysis for comparison of experimental and FEM based approach. FEM based simulation analysis has been performed on developed gearbox which can be further validated by experiment in future. Maintain acceptable oil sump temperature in gearbox is critical to its life. Objective of thermal analysis is to find the amount of temperature induced inside gearbox casing and amount of cooling requirement, if necessary. The thermal analysis performed on existing gearbox for validation of present work experimentally as well as analytically. Analytical thermal analysis has been performed on developed gearbox which can be further validated by experiment in future. The amount of the cooling required for developed gearbox is found out.