DESIGN AND ANALYSIS OF SPUR GEAR BY

USING BLACK FIBER, E-GLASS FIBER AND

CARBON FIBER WITH ISOPOLYMER
 ABSTRACT
• Hybrid Composite material have evoked a keen interest in
recent times for potential applications in aerospace and
automotive industries owing to their superior strength to
weight ratio and temperature resistance. The widespread
adoption of particulate metal matrix composites for
engineering applications has been hindered by the high cost
of producing components.
• Achieving a uniform distribution of reinforcement within
the matrix is one such challenge, which affects directly on
the properties and quality of composite material.
• This paper discuss the Spur Gear model made by black
fibre, E-glass fiber and carbon fiber with isopolymer
composite material and to evaluate the tensile, Hardness,
wear Strength of the Composite Material.
 INTRODUCTION
• A composite material can be defined as a combination of two or more materials that
results in better properties than those of the individual components used alone. In
contrast to metallic alloys, each material retains its separate chemical, physical, and
mechanical properties. The two constituents are reinforcement and a matrix. The
main advantages of composite materials are their high strength and stiffness,
combined with low density, when compared with bulk materials, allowing for a
weight reduction in the finished part.
• The reinforcing phase provides the strength and stiffness. In most cases, the
reinforcement is harder, stronger, and stiffer than the matrix. The reinforcement is
usually a fiber or a particulate. Particulate composites have dimensions that are
approximately equal in all directions. They may be spherical, platelets, or any other
regular or irregular geometry. Particulate composites tend to be much weaker and
less stiff than continuous fiber composites, but they are usually much less
expensive. Particulate reinforced composites usually contain less reinforcement (up
to 40 to 50 volume percent) due to processing difficulties and brittleness. A fiber
has a length that is much greater than its diameter. The length-to-diameter (l/d) ratio
is known as the aspect ratio and can vary greatly.
 Literature review
Name Reference

[K. Mao, 2006 The detailed analysis of the flash temperature for polymer
composite gears and the heat partition between gear teeth
problem is treated as an unsteady one where the intensity
distribution and velocity of heat source changes as meshing
proceeds.
[J.L. Moya, A.S. They have performed a theoretical analysis of a procedure to
Machado, 2007] determine the Lewis Factor and also performed the contact analysis
of spur gears to find the stress distribution between gear teeth. It is
to establish a characterization method for seven polyamide (PA)
grades to determine the major material to manufacture an
automotive worm gear. The composite properties were measured
according to the worm gear loadings: tensile strength, Young's
modulus, abrasion and impact resistance. They were also
correlated to the PA moisture absorption and its glass fiber (GF)
reinforcement.
 Literature review
Name Reference

The objective of this research was to gain a better understanding of

BanakarPrashan Mechanical properties of epoxy resin composites reinforced with
th&Shivananda carbon Fibre. The effect of Fibre orientation of laminates has been
H.K. investigated & experimentation was performed to determine
property data for material specifications, the laminates were
obtained by hand layup process. The laminates were cut to obtain
ASTM standards. This investigation deals with the testing of tensile
and flexural strength on a universal testing machine.
Kumar Santhosh This project presents the study of tensile, flexural & moisture
M, Dr. S. G. absorption properties of composites made from Sglass, Carbon and
Gopala Krishna E-glass Fibre. The specimens are prepared using hand lay-up
&Dr.Rajanna. S techniques as per ASTM standard for different thickness 2mm and
3mm and Fibre orientation of 30º, 45º and 60º, where an attempt
is made to study the properties of composite materials by
composing the different materials together to obtain the desired
properties by increasing the thickness and Fibre orientation.
PROCESS FLOW
 COMPOSITION
• BLACK FIBER -10%
• E-GLASS FIBER - 25%
• CARBON FIBER - 10%
• ISOPOLYMER -55%
SPUR GEAR
BLACK FIBER
 MATERIALS PREPARATIONS
• The black fiber which is taken as reinforcement
in this study is collected from local sources. The
epoxy resin and the hardener are supplied.
Wooden mould having been first manufactured
for composite fabrication. The fiber material is
mixed epoxy resin by simple mechanical stirring
and the mixture was poured into various mould,
keeping in view the requirement of various
testing conditions and characterization standard.
 E-GLASS
E GLASS –
Alumina-calcium-borosilicate glasses
with a maximum alkali content of 2 wt.%
used as general purpose fibers where
strength and high electrical resistivity are
required
E-GLASS IMAGES
 PROPERTIES OF E-GLASS
PROPERTIES VALUE

Specific gravity 2.52-2.62

Tensile strength 3100-3800 MPa

Elastic modulus 72.5-75.5Gpa

Elongation at break 4.7 %

CARBON FIBER
 CARBON FIBER PROPERTIES

Properties value

Density (g/m^3) 1.77

Tensile Modulus GPa 238

Tensile Strength MPa 3950

Percentage tensile elongation 1.5

 ISOPOLYMER
ISOPOLYMERS are widely used in various industrial fields
due to their merits, such as light weight, resistance to
chemicals, resistance to the environment, easy processing,
etc. It is difficult for polymers to be treated after use due to
their resistance to the environment. When polymers are
disposed of in natural environment, they remain for a long
time without degradation. One of the solutions to this
problem of polymers after use is the development of
biodegradable polymers. Biodegradable polymers can be
biodegraded eventually by microorganisms in the natural
environment into carbon dioxide(CO2) and water (H2O).
Various types of biodegradable plastics have been
developed.
ISOPOLYMER
PROPERTIES OF ISOPOLYMER
PROPERTIES VALUE

Density (g/cm³) 1.15

Tensile strength (Mpa) 70-80

Young’s modulus (Gpa) 3.5

Elongation at break (%) 4-6

 CHARACTERISTICS OF SYNTHETIC
FIBER
• It is highly strong fiber.
• It is light weight
• tough and durable
• unaffected by moisture and dampness
 DIE MAKING
• The tooling involved in plastic molding is quite
similar to that of stamping dies. The principal
difference is that stamping requires force, while
molding does not. In plastic molding, two units
are required whose design is such that, when
brought together, they make up a system of closed
cavities linked to a central orifice. Liquid plastic
is forced through the orifice and into the cavities,
or molds, and when the plastic solidifies, the
molds open and the finished parts are ejected.
 APPLICATIONS
• AUTOMOBILE COMPONENTS
• INDUSTRIES
• TIDAL POWER PLANT COMPONENTS.
 EXISTING APPLICATIONS

• Automobile parts such as rear view mirror, visor in two

wheeler, billion seat cover, indicator cover, cover L-side, name
plate were fabricated using sisal and roselle fibers hybrid
composites
• decks, docks, window frames and molded panel components
 TESTS ARE INVOLVING
• TENSILE TEST
• HARDNESS TEST
• WEAR TEST
ULTRASONIC TESTING MACHINE
KNOP HARDNESS TEST
IMPACT TEST
 ADVANTAGES OF FIBER COMPOSITES
• As molded dimensional accuracy. Tight tolerance,
repeatable moldings.
• Chemical Resistance.
• Consolidated Parts and Function.
• Corrosion Resistance.
• Design Flexibility.
• Durable.
• High Flexural Modulus to Carry Demanding
Loads. High Impact Strength.
• High Performance at Elevated Temperatures.
 Conclusion
The literature survey of fiber composite spur gear was
performed:

• Then the study in weight reduction and stress distribution

of spur gear for black, e-glass and carbon fiber composite
materials has been done.
• On the basis of that study, the analysis of both cast AL and
fiber composite materials are analyzed in the application of
gear which is used in automobile vehicles.
• From the analysis we got the hardness and impact values
for fiber composite materials weight and cost is less.
• So from these analysis mechanical behavior results.
 REFERENCE
• S.A.H. Roslan, Z.A. Rasid, M.Z. Hassan, The synthetic fiber
composites based on glass fibers; A review, ARPN journal of
engineering and applied science, Vol. 10, No. 15, Aug 2015.
• Parnia Zakikhani, R. Zahari, M.T.H. Sultan, D,L. Majjid, black
fiber-reinforce composites, Materials and design 63 (2014)
820-828
• R. J. Diefendorf, Carbon/Graphite Fibers, Composites, Vol 1,
Engineered Materials Handbook, ASM International, 1987, p
52
• Plant Fiber – Industrial Waste Reinforced PolymerComposites
As A Potential Wood Substitute Material”,Journal of
Composite Materials, 2008, Volume 42,Issue 4, pp 367 - 384.