JIMMA UNIVERSITY JIT DEPARTMENT OF MECHANICAL ENGINEERING

WORM REDUCER GEARBOX

CAD/CAM Project

Group 3
Sub Group 3

MEng 4133: CAD/CAM Final Project

Department of Mechanical Engineering Jimma Instit te of !echnolog" Jimma #ni$ersit" Jimma% Ethiopia DE&I'( A(D A&&EM)*+ ,F A -,.M .ED#CE. 'EA.),/ #&I(' CA!IA 012.13
)" 'ro p 3 & 4 'ro p 3 Mem4ers

#n5er s per$ision of Engr6 .omano 'a4rillo% Assistant Professor

!EC7(ICA* .EP,.! &#)MI!!ED I( F#*FI*ME(! ,F !7E .E8#I.ME(! ,F MEng 4133

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14th of Jan ar"% 9:14

'ro p Mem4ers 'ro p *ea5er 2 < *emi Chala => Name

1* 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 *emi Chala Mesa" Cher Megersa *elisa *ingere@ Em4aAom Cassah n Dessalegn *elisa ,ljira 7"ra5in &ho@molo (atnael &isa" M stefa M Ee"in Cef"ale@ )elete Min"ahil )e@ net (igat Ermias M lgeta Demisse MoAonen Asmare Ca"o )a4

ID NO.
:11?1/:3 :193?/:3 :931?/:3 :941B/:3 :339D/:3 :9441/:3 :131:/:3 :134:/:3 :3331/:3 :1993/:9 :13B9/:3 :1391/:3 :1914/:3 :911B/:3

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A4stract
CATIA is a universal so !"are use# in various in#us!ries$ in%lu#in& aeros'a%e$ %ons!ru%!ion$ ma%(iner)$ an# ele%!roni%s. One o !(e mos! remar*a+le ea!ures o CATIA ,5 is !(e #iversi!) o "or*+en%(es in !(e me%(ani%al #esi&n se%!ion$ ma*in& !(e #esi&ne# 'ar!s #is!in&uis(a+le. T(e #esi&n 'ro%ess o%%urs !(rou&( se-uen!ial s!a&es s!ar!in& rom !(e ini!ial #esi&n !o !(e a%!ual #evelo'men! o !(e 'ro#u%!. T(e aim o !(is 'ro.e%! is !o #esi&n a "orm re#u%er &ear+o/ "i!( i!s #e!aile# %om'onen!s usin& CATIA. T(e a%ili!ies 'rovi#e# +) !(is so !"are (el' !o #esi&n an%) sur a%es an# irre&ularl) s(a'e# 'ar!s$ an# i/ !(e 'ossi+le in!er eren%es !(a! ma) o%%ur #urin& !(e assem+l) o !(ese 'ar!s !o avoi# an) u!ure 'ro+lems. Anima!ion simula!ion re%or#in& "ill +e 'la)e# !o s(o" some #e!aile# ea!ures.

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Intro5 ction
T(e ne" &enera!ion o CAD 0Com'u!er Ai#e# Desi&n1 so !"are ollo"e# !(e ra'i# 'ro&ress in in#us!r)$ o%usin& on manu a%!or). 2a!el)$ (i&(l) #evelo'e# an# %om'le/ ea!ures "ere in!ro#u%e# !o em'o"er CAD so !"are$ allo"in& i! !o sa!is ) !(e a#van%e# re-uiremen!s #i%!a!e# +) !(e ne" in#us!r). CATIA$ 3ro4 en&ineer$ Au!o#es*$ an# Inven!or are !(e mos! %ommonl) use# so ! "ares in !(is iel#. T(e main %on%ern o !(is 'ro.e%! is !o use CATIA ,5 !o e/'lore an# o'!imi5e !(e #i eren! ea!ures an# un%!ions o !(e #esi&n. To a%(ieve !(is !as*$ !ransi!ion +e!"een "or*+en%(es insi#e !(e me%(ani%al #esi&n se%!ion "as assure# !o a!!ain !(e mos! easi+le s(a'e. A !er %om'le!in& !(e #esi&n$ !(e &enera!e# 'ar!s "ere assem+le# an# all 'ossi+le in!er eren%es "ere %(e%*e# !o 'reven! %las(es. 6a%( 'ar! o !(e "orm re#u%er &ear+o/ "as #ra"n se'ara!el) usin& CATIA$ ensurin& !(e #is'la) o all en%lose# #e!ails. A !er assem+lin& !(ese 'ar!s$ an anima!ion simula!ion "as %ons!ru%!e# !o #emons!ra!e !(e main me%(ani%al ea!ures o !(e #esi&ne# 'ro#u%!.

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Fig re 1: 7orm 8e#u%er 9ear+o/ Assem+l)

-orAing Principle of -orm .e5 cer 'ear4o;

A "orm re#u%er &ear+o/ o'era!es +ase# on !(e 'rin%i'le o @orm 5ri$e% "(i%( is a &ear arran&emen! in "(i%( a @orm 0"(i%( is a &ear in !(e orm o a s%re"1 mes(es "i!( a @orm gear 0"(i%( is similar in a''earan%e !o a s'ur &ear$ an# is also %alle# a @orm @heel1.

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. Fig re 9: 7orm #rive 2i*e o!(er &ear arran&emen!s$ a "orm #rive %an re#u%e ro!a!ion s'ee# or allo" (i&(er !or-ue !o +e !ransmi!!e#. A &ear+o/ #esi&ne# usin& a "orm an# "orm4"(eel "ill +e %onsi#era+l) smaller !(an one ma#e rom 'lain s'ur &ear an# (as i!s #rive a/es a! 90; !o ea%( o!(er. 7i!( a single start "orm$ or ea%( 360; !urn o !(e "orm$ !(e "orm4&ear a#van%es onl) one !oo!( o !(e &ear. T(ere ore$ re&ar#less o !(e "orm<s si5e$ !(e &ear ra!io is !(e "size of the worm gear - to - 1". 9iven a sin&le s!ar! "orm$ a 20 !oo!( "orm &ear "ill re#u%e !(e s'ee# +) !(e ra!io o 20:1. 7i!( s'ur &ears$ a &ear o 12 !ee!( 0!(e smalles! si5e 'ermissi+le$ i #esi&ne# !o &oo# en&ineerin& 'ra%!i%es1 "oul# (ave !o +e ma!%(e# "i!( a 240 !oo!( &ear !o a%(ieve !(e same ra!io o 20:1. T(ere ore$ i !(e #iame!ri%al 'i!%( 0D31 o ea%( &ear "as !(e same$ !(en$ in !erms o !(e '()si%al si5e o !(e 240 !oo!( &ear !o !(a! o !(e 20 !oo!( &ear$ !(e "orm arran&emen! is %onsi#era+l) smaller in volume.

!"pes of -orm Dri$es

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T(ere are !(ree #i eren! !)'es o &ears !(a! %an +e use# in a "orm #rive. 1. T(e irs! are non-throated "orm &ears. T(ese #on<! (ave a throat$ or &roove$ ma%(ine# aroun# !(e %ir%um eren%e o ei!(er !(e "orm or "orm "(eel. 2. T(e se%on# are single2throate5 "orm &ears$ in "(i%( !(e "orm "(eel is !(roa!e#. 3. T(e inal !)'e are 5o 4le2throate5 "orm &ears$ "(i%( (ave +o!( &ears !(roa!e#. T(is !)'e o &earin& %an su''or! !(e (i&(es! loa#in&. 1. An en$eloping Fho rglassG "orm (as one or more !ee!( an# in%reases in #iame!er rom i!s mi##le 'or!ion !o"ar# +o!( en#s. 2. Do 4le2en$eloping "orm &earin& %om'rises envelo'in& "orms ma!e# "i!( ull) envelo'in& "orm &ears. I! is also *no"n as glo4oi5al "orm &earin&.

Direction of !ransmission
=nli*e "i!( or#inar) &ear !rains$ !(e #ire%!ion o !ransmission 0in'u! s(a ! versus ou!'u! s(a !1 is no! reversi+le "(en usin& lar&e re#u%!ion ra!ios$ #ue !o !(e &rea!er ri%!ion involve# +e!"een !(e "orm an# "orm4"(eel$ "(en usuall) a sin&le s!ar! 0one s'iral1 "orm is use#. T(is %an +e an a#van!a&e "(en i! is #esire# !o elimina!e an) 'ossi+ili!) o !(e ou!'u! #rivin& !(e in'u!. I a mul!is!ar! "orm 0mul!i'le s'irals1 is use# !(en !(e ra!io re#u%es a%%or#in&l) an# !(e braking effect o a "orm an# "orm4&ear ma) nee# !o +e #is%oun!e# as !(e &ear ma) +e a+le !o #rive !(e "orm. 7orm &ear %on i&ura!ions in "(i%( !(e &ear %anno! #rive !(e "orm are sai# !o +e self-locking. 7(e!(er a "orm an# &ear "ill +e sel 4lo%*in& #e'en#s on !(e lea# an&le$ !(e 'ressure an&le$ an# !(e %oe i%ien! o ri%!ion> (o"ever$ i! is a''ro/ima!el) %orre%! !o sa) !(a! a "orm an# &ear "ill +e sel 4lo%*in& i !(e !an&en! o !(e lea# an&le is less !(an !(e %oe i%ien! o ri%!ion.

Application
7orm #rives are a %om'a%! means o su+s!an!iall) #e%reasin& s'ee# an# in%reasin& !or-ue. ?mall ele%!ri% mo!ors are &enerall) (i&(4s'ee# an# lo"4!or-ue> !(e a##i!ion

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o a "orm #rive in%reases !(e ran&e o a''li%a!ions !(a! i! ma) +e sui!a+le or$ es'e%iall) "(en !(e "orm #rive<s %om'a%!ness is %onsi#ere#. 7orm #rives are use# in 'resses$ in rollin& mills$ in %onve)in& en&ineerin&$ in minin& in#us!r) ma%(ines$ an# on ru##ers. In a##i!ion$ millin& (ea#s an# ro!ar) !a+les are 'osi!ione# usin& (i&(4're%ision #u'le/ "orm #rive "i!( a#.us!a+le +a%*las(. 7orm &ears are use# on man) li !@eleva!or an# es%ala!or4#rive a''li%a!ions #ue !o !(eir %om'a%! si5e an# !(e non4reversi+ili!) o !(e &ear. 7orm #rives are use# as !(e !unin& me%(anism or man) musi%al ins!rumen!s$ in%lu#in& &ui!ars$ #ou+le4+asses$ man#olins$ +ou5ou*is$ an# man) +an.os 0al!(ou&( mos! (i&(4en# +an.os use 'lane!ar) &ears or ri%!ion 'e&s1. A "orm #rive !unin& #evi%e is %alle# a ma%(ine (ea#. 3las!i% "orm #rives are o !en use# on small +a!!er)4o'era!e# ele%!ri% mo!ors$ !o 'rovi#e an ou!'u! "i!( a lo"er an&ular velo%i!) 0 e"er revolu!ions 'er minu!e1 !(an !(a! o !(e mo!or$ "(i%( o'era!es +es! a! a airl) (i&( s'ee#. T(is mo!or4 "orm4&ear #rive s)s!em is o !en use# in !o)s an# o!(er small ele%!ri%al #evi%es. A "orm #rive is use# on .u+ilee4!)'e (ose %lam's or .u+ilee %lam's> !(e !i&(!enin& s%re" (as a "orm !(rea# "(i%( en&a&es "i!( !(e slo!s on !(e %lam' +an#. O%%asionall) a "orm &ear is #esi&ne# !o +e run in reverse$ resul!in& in !(e ou!'u! s(a ! !urnin& mu%( as!er !(an !(e in'u!. 6/am'les o !(is ma) +e seen in some (an#4%ran*e# %en!ri u&es or !(e "in# &overnor in a musi%al +o/.

Project ,$er$ie@
T(e CAD 3ro.e%!$ -orm re5 cer gear4o; is %om'ose# o : 1. 6/'lo#e# ,ie" o Assem+le# 'ar!s. 3. T(is #o%umen! 0.DOC orma!1.

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MEng 4133: CAD/CAM Final Project 4. CAD s%reens(o!s s(o"in& !(e ren#ere# ima&es o !(e 'ar!s an# !(e assem+lies. 5. CAD assem+l) an# 'ar! #esi&ns or CATIA ,ersion 5$ 8elease 19 or (i&(er

0a+ou! 3 assem+l) #esi&ns an# 17 'ar! #esi&ns1. 6. Dra !e# 'ar!s an# #ra !e# assem+l) #ra"in&. In o!(er "or#s$ !(e "orm re#u%er &ear+o/ me%(anism is #es%ri+e# on: 34#imensional CAD #ra"in&s. 24#imensional !e%(ni%al #ra !s$ &enera!e# rom !(e CAD #ra"in&s. 7. Anima!e# 6/'lo#e# vie" reassem+l).
PA.! (#M)E . 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 DE&C.IP!I,( ,F PA.! 7orm s(a ! +ol! 7orm "(eel +ol! Aus( o "orm "(eel s(a ! Aus( o "orm s(a ! Cover o "orm "(eel s(a ! Cover 1 o "orm s(a ! Cover 2 o "orm s(a ! 9ear Bouse Aase 9ear Bouse Cover I?OC4014CD14/60C?9BBNCAO2T I?OC4032CD14C?9NBCN=T Ee) o "orm "(eel T(rus! +all +earin& 7orm s(a ! 7orm "(eel 7orm "(eel %en!er 7orm "(eel s(a !

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Part Dra@ings
16'ear 7o se )ase

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96'ear 7o se #pper Co$er

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36 -orm &haft

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46 -orm -heel Center

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16 -orm -heel &haft

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?6 -orm -heel

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Assem4l" Dra@ing

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MEng 4133: CAD/CAM Final Project

E;plo5e5 0ie@ Dra@ing

16-orm -heel an5 &haft Assem4l"

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MEng 4133: CAD/CAM Final Project

96 -orm shaft 2 !hr st 4earing 2 -orm 4 sh

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Concl sion
7(ile %arr)in& ou! !(is 'ro.e%!$ "e mana&e# !o #is%over an# use !(e varie# un%!ions a''lie# !o !(e #i eren! "or*+en%(es$ su%( as 'ar! #esi&n$ assem+l) an# #ra !in&. Dan) %(allen&es "ere a%e# an# surmoun!e#> (o"ever$ !(e main one "as en%oun!ere# "(en in !(e assem+l) "or*+en%($ !r)in& !o ensure !(a! no in!er eren%es e/is! +e!"een i!s 'ar!s. ?u%( !as* "as su%%ess ull) a%%om'lis(e#$ !(an*s !o !(e %las( anal)sis "(i%( a%ili!a!e# !(e %(e%* over. T(e DD= Fi!!in&s an# 3(o!o s!u#io "as also e/'lore# !o %rea!e a ren#ere# ima&e an# e/'lo#e# vie" anima!ion o some me%(ani%al ea!ures o !(e 'ro#u%!. In %on%lusion$ all o'era!ions "ere %on#u%!e# e e%!ivel) lea#in& !o !(e +ir!( o !(e "orm re#u%er &ear+o/.

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