Optimization & Analysis of Forging Press Gear Box

Gears are the most important component in a power transmission system. Their effectiveness should not decrease with a constant prolonged application and should have well anti wear properties. The assembled gear transmits mechanical energy from a prime mover to an output device. A gearbox can also change the speed, direction, or torque of mechanical energy. Gear box is indicated when the application involves high speeds, large power transmission where noise abatement is important. Thus gear needs to be redesigned, providing energy saving by weight reduction, providing internal damping, reducing lubrication requirements, without increasing cost. This work is to explore the development of composite automotive gear box with optimum design and composite material selection at conceptual design stage for weight reduction to get better fuel efficiency with fulfilling needs of anti-fade characteristics, less power loses due to weight, corrosion resistant design and more consolidated design. The demands of material performances are so great and diverse that no one material is able to satisfy them. Composite material system results in a performance unattainable by the individual constituents. Composite materials offer the advantage of a flexible design that can be tailored to the design requirements. The specific composite materials Glass filled polyamide in particulate form is used for herringbone gears owing to better strength, recyclability, low density and less friction. Glass/epoxy is used for gear housing and shafts for strength requirements, orthotropic properties. Finite element analysis allows entire designs to be constructed, refined, and optimized before the design is manufactured with dynamic effects in low cost.