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A Project Report on
Submitted By: Muhammad Saqib Anwar Muhammad Nouman Mudassir Hussain Hamza Ahmed 32-Mechanical (B) Date: May 29th, 2012
Submitted to: Engr Akhtar Khurshid Assistant Professor Department of Mechanical Engineering, College of E&ME, NUST
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Table of Contents
A bstract .............................................................................................................................. 1 P roject Overview .............................................................................................................. 1 External G ear P um p ........................................................................................................ 1 Theory of Operation .......................................................................................................... 2 Literature R eview ............................................................................................................. 3 Technical D etails ............................................................................................................... 4 Gears ............................................................................................................................. 4 Bearings ......................................................................................................................... 6 Shafts ............................................................................................................................. 7 Housing .......................................................................................................................... 8 M anufacturing P rocesses Involved ................................................................................ 9 Gear Hobbing................................................................................................................ 10 Sand Casting ................................................................................................................. 11 Machining ..................................................................................................................... 11 Grinding........................................................................................................................ 12 Press Fitting ................................................................................................................. 13 C alculations for D ischarge R ate of a G ear P um p ..................................................... 14 A dvantages and A pplications of an External G ear P um p ..................................... 15 C onclusion ........................................................................................................................ 17 R eferences ........................................................................................................................ 17
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P roject Overview
A gear pump uses the meshing of gears to pump fluid by displacement. They are one of the most common types of pumps for hydraulic fluid power applications. Gear pumps are also widely used in chemical installations to pump fluid with a certain viscosity. There are two main variations; external gear pumps which use two external spur gears, and internal gear pumps which use an external and an internal spur gear. Gear pumps are positive displacement (or fixed displacement), meaning they pump a constant amount of fluid for each revolution. The motive of this project is to design and fabricate an external gear pump.
External G ear P um ps
External gear pumps are a popular pumping principle and are often used as lubrication pumps in machine tools, in fluid power transfer units, and as oil pumps in engines. External gear pumps can come in single or double (two sets of gears) pump configurations with spur (shown), helical, and herringbone gears. Helical and herringbone gears typically offer a smoother flow than spur gears, although all gear types are relatively smooth. Large-capacity external gear pumps typically use helical or herringbone gears. Small external gear pumps usually operate at 1750 or 3450 rpm and larger models operate at speeds up to 640 rpm. External gear pumps have close tolerances and shaft support on both sides of the gears. This allows them to run to pressures beyond 3,000 psi / 200 bar, making them well suited for use in hydraulics. With four bearings in the liquid and tight tolerances, they are not well suited to handling abrasive or extreme high temperature applications. Tighter internal clearances provide for a more reliable measure of liquid passing through a pump and for greater flow control. Because of this, external gear pumps
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are popular for precise transfer and metering applications involving polymers, fuels, and chemical additives.
Theory of Operation
External gear pumps are similar in pumping action to internal gear pumps in that two gears come into and out of mesh to produce flow. However, the external gear pump uses two identical gears rotating against each other -- one gear is driven by a motor and it in turn drives the other gear. Each gear is supported by a shaft with bearings on both sides of the gear. 1. As the gears come out of mesh, they create expanding volume on the inlet side of the pump. Liquid flows into the cavity and is trapped by the gear teeth as they rotate. 2. Liquid travels around the interior of the casing in the pockets between the teeth and the casing -- it does not pass between the gears. 3. Finally, the meshing of the gears forces liquid through the outlet port under pressure.
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Because the gears are supported on both sides, external gear pumps are quietrunning and are routinely used for high-pressure applications such as hydraulic applications. With no overhung bearing loads, the rotor shaft can't deflect and cause premature wear.
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Literature R eview
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Figure 2. Pumping Action of an External Gear Pump
Gear pumps are among the oldest and most commonly used pumps within the industry. Though the gear pump is extremely simple in its operating principle, the fundamental understanding of the instantaneous pump flow has been a subject of considerable interest for many years. The complexity of this subject arises due to the nature of the geometry involved, which has typically required numerical analysis to solve the governing equations. Much of the recent research that is most germane to gear pump technology is briefly summarized in the following paragraph. Research pertaining to the average flow rate of the gear pump has been conducted by Frith and Scott [1]. In their work, the authors have related the degradation of the average flow rate to the online generation of wear debris. In other research, authors have emphasized a prediction in the fluid film thickness between the gear end-face and the end wear-plate [2]. In this work, the authors were primarily concerned with volumetric leakage and pump efficiency. For predicting the cyclic moments and forces on the pump shaft, Foster, Taylor, and Bidhendi [5] conducted an in depth analysis of the gear pump using a computer program for generating solutions. This work considered the trapped volume of fluid between meshing teeth and the results were shown to compare nicely with actual test data. Still, others have focused on various tooth geometries in an effort to reduce and/or compare the discharge flow amplitude of the pump [7]. Though all of this work has been valuable in and of itself, none of this work has considered a comparison of same-size external gear pumps, which use different numbers of teeth for the driving and driven gears. The question related to tooth number is significant since other positive-displacement pump types
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tend to exhibit different flow characteristics depending upon the number of discrete pumping elements that are used. For instance, axial piston pumps have been shown to exhibit significantly different pulse shapes for pumps that use an even versus an odd number of pistons [8]. This present study is aimed at design and fabrication of an external gear pump.
Technical D etails
From an engineering perspective, Product design is a critical activity because it has been estimated that, generally, 70 to 80% of the cost of product development and manufacture is determined at the initial design stages. So, designing a product meeting the international standards (ANSI, ASME, ASTM, ISO, SAE etc.) is a prerequisite to machine functionality and design viability. Keeping in view the above scenario, we devised a Gear Pump optimized for industrial applications. The specifications of various components of an External Gear Pump are enlisted below.
i. G ears
A gear is a rotating machine part having cut teeth, or cogs, which mesh with another toothed part in order to transmit torque. Two or more gears working in tandem are called a transmission and can produce a mechanical advantage through a gear ratio and thus may be considered a simple machine. Geared devices can change the speed, torque, and direction of a power source. The most common situation is for a gear to mesh with another gear, however a gear can also mesh a non-rotating toothed part, called a rack, thereby producing translation instead of rotation. The gears in a transmission are analogous to the wheels in a pulley. An advantage of gears is that the teeth of a gear prevent slipping. In transmissions which offer multiple gear ratios, such as bicycles and cars, the term gear, as in first gear, refers to a gear ratio rather than an actual physical gear. The term is used to describe similar devices even when gear ratio is continuous rather than discrete, or when the device does not actually contain any gears, as in a continuously variable transmission. The gear used in our project was a spur gear.
G ear Specifications The specifications of gear used in our project are enlisted in the table given in the proceeding page. Below is a diagram representing the nomenclature of a spur gear.
M aterial
N o. of teeth (N ) 11
Steel NK11B
ii. B earings
A bearing is any of various machine elements that constrain the relative motion between two or more parts to only the desired type of motion. This is typically to allow and promote free rotation around a fixed axis or free linear movement; it may also be to prevent any motion, such as by controlling the vectors of normal forces. Bearings may be classified broadly according to the motions they allow and according to their principle of operation, as well as by the directions of applied loads they can handle.
B earing Specifications B oundary dim ensions (m m ) P art N o. Bore (A) 25 Outer diameter (B) 52 Width (C) 15 B asic load ratings (N ) Dynamic (Cr) 14000 Static (Cor) 7900 0.810 W eight (lb)
6205
B earing M aterial Specifications Material Used: CS6208XXPKWS C Ball material: C=Ceramic (Si3N4) No symbol = Chrome Steel S Ring Material: No symbol = Chrome steel S=Stainless Steel (440C) XX Closure: XX=Open (Standard bearing width, no seal) No Symbol = Open (Narrow bearing width, no seal) PK Retainer material: PK=PEEK No Symbol = Metal WS Lubrication: Dry film lubrication/ Coating WS=Tungsten Disulfide
iii. Shaft
Shaft is a mechanical component for transmitting torque and rotation, usually used to connect other components of a drive train that cannot be connected directly because of distance or the need to allow for relative movement between them. Shafts are carriers of torque: they are subject to torsion and shear stress, equivalent to the difference between the input torque and the load. They must therefore be strong enough to bear the stress, whilst avoiding too much additional weight as that would in turn increase their inertia. M aterial U sed: Mild Steel
iv. H ousing
Housing is an important component of gear pump, which is used in order to prevent leakage. This factor is quite significant while designing a gear pump. Below are the 2-D sketches of various components used in housing of gear pump. The Material used was aluminum.
Figure 7. This figure represents the lower portion of housing. The upper portion was the replica of lower portion. The bearings are fitted in the holes shown in the figure.
Figure 8. This figure represents the central portion of housing. The gears are fitted in this portion.
The significant processes used in our project include Gear Hobbing, Wood Working, Sand Casting, Machining, Grinding and Press Fitting.
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I. G ear H obbing
There are different processes by which gears can be generated such as Form Milling, Gear Hobbing, Gear Shaping, Gear Broaching etc.; however we used the hobbing process. Gear hobbing is also a milling operation, but the cutter, called a hob, is much more complex and therefore much more expensive than a form milling cutter. In addition, special milling machines (called hobbing machines) are required to accomplish the relative speed and feed motions between the cutter and the gear blank. Gear hobbing is illustrated in Figure 10. As shown in the figure, the hob has a slight helix and its rotation must be coordinated with the much slower rotation of the gear blank in order for the hobs cutting teeth to mesh with the blanks teeth as they are being cut. This is accomplished for a spur gear by offsetting the axis of rotation of the hob by an amount equal to 90 less the helix angle relative to the axis of the gear blank. In addition to these rotary motions of the hob and the workpiece, a straight-line motion is also required to feed the hob relative to the gear blank throughout its thickness. Several teeth are cut simultaneously in hobbing, which allows for higher production rates than form milling. Accordingly, it is a widely used gear making process for medium and high production quantities.
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Figure 11. Steps in the production sequence in sand casting. The steps include not only the casting operation but also pattern making and mold making.
III. M achining
Machining is the most widely used manufacturing processes, because most of the industrial products have to be machined in order to bring them to net shape. For example, bar stock is the initial shape, but the final geometry after a series of machining operations is a shaft. Innumerable machining operations are performed in
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industries to achieve dimensional accuracies and other purposes, but we shall enlist few of those used in our project.
Facing: The tool is fed radially into the rotating work on one end to create a flat
surface on the end.
Threading: A pointed tool is fed linearly across the outside surface of the rotating
workpart in a direction parallel to the axis of rotation at a large effective feed rate, thus creating threads in the cylinder.
B oring: A single-point tool is fed linearly, parallel to the axis of rotation, on the
inside diameter of an existing hole in the part.
D rilling: Drilling can be performed on a lathe by feeding the drill into the rotating
work along its axis. Reaming can be performed in a similar way. These machining operations are illustrated in Figure given below.
Facing
Threading
Boring
IV . G rinding
Grinding is a material removal process accomplished by abrasive particles that are contained in a bonded grinding wheel rotating at very high surface speeds. The grinding wheel is usually disk-shaped, and is precisely balanced for high rotational
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speeds. Grinding can be likened to the milling process. Cutting occurs on either the periphery or the face of the grinding wheel, similar to peripheral and face milling. Peripheral grinding is much more common than face grinding. The rotating grinding wheel consists of many cutting teeth (the abrasive particles), and the work is fed relative to the wheel to accomplish material removal. Despite these similarities, there are significant differences between grinding and milling: (1) the abrasive grains in the wheel are much smaller and more numerous than the teeth on a milling cutter; (2) cutting speeds in grinding are much higher than in milling; (3) the abrasive grits in a grinding wheel are randomly oriented and possess on average a very high negative rake angle; and (4) a grinding wheel is self-sharpeningas the wheel wears, the abrasive particles become dull and either fracture to create fresh cutting edges or are pulled out of the surface of the wheel to expose new grains.
V . P ress Fitting
A press fit assembly is one in which the two components have an interference fit between them. The typical case is where a pin (e.g., a straight cylindrical pin) of a certain diameter is pressed into a hole of a slightly smaller diameter. Standard pin sizes are commercially available to accomplish a variety of functions, such as (1) locating and locking the componentsused to augment threaded fasteners by
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holding two (or more) parts in fixed alignment with each other; (2) pivot points, to permit rotation of one component about the other; and (3) shear pins. Except for (3), the pins are normally hardened. Shear pins are made of softer metals so as to break under a sudden or severe shearing load to save the rest of the assembly. Other applications of press fitting include assembly of collars, gears, pulleys, and similar components onto shafts.
Figure 14. Cross section of a solid pin or shaft assembled to a collar by interference fit.
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C onversions
Center Distance = 2.4 in. = 0.6096 dm Outside Diameter = 2.8 in. = 0.7112 dm Face = 1.750 in. = 0.4445 dm Speed = 1500 rpm Q = 0.95C(D C )lN Q = (0.95)(3.14)(0.6096)(0.7112 0.6096)(0.4445)(1500) Q = 123.25 lpm
efficiency. Slip depends on the magnitude of the differential pressure (i.e., the difference between the discharge and suction pressures), the viscosity of the liquid pumped and the working clearances inside the particular pump that is used. Slip increases with decreasing viscosity, increasing differential pressure and increasing gear-housing clearances, and is usually measured as a percent decrease from ideal flow (i.e., flow with zero slip). For fluid viscosities greater than about 50-100 cP (depending on the particular pump), the slip is minor, but it still depends on the differential pressure. This behavior is shown in Figure 15, which compares a typical gear pumps performance curve for a thin fluid (such as water with a viscosity of about 1 cP at room temperature) with that of a moderately viscous fluid (such as a particular oil with a viscosity of 100 cP).
Figure 15. Performance curves for a typical external gear pump showing slip as a function of viscosity and differential pressure.
Gear pumps properly designed and engineered can offer many advantages. These include compactness, simplicity of design, easy serviceability, bi-directional flow capability, ability to self-prime, pulseless flow, low NPSHR (net positive suction head required), high MTBM (mean time between maintenance), high-pressure and high-temperature capability, precise and accurate metering, and availability in multiple seal configurations or sealless mag-drives. External gear pumps are used in
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industrial and mobile (e.g. log splitters, lifts) hydraulic applications. Typical applications include: Lubrication pumps in machine tools Fluid power transfer units Oil pumps in engines Circulation Injection Drum transfer Chemical additive and polymer metering Chemical mixing and blending (double pump) Acids and caustic (stainless steel or composite construction)
C onclusion
In short, Gear Pumps are used in many industrial applications and manufacturing processes are a key element in the designing and functionality of gear pump. All we need to do is to apply these manufacturing processes effectively, so that we can upheave our industry.
R eferences
[1]. Frith, R. H., and Scott, W., 1996, Comparison of an external gear pump wear model with test data, Wear,196, pp. 64 71. [2]. Koc, E., and Hooke, C. J., 1997, An experimental investigation into the design and performance of hydrostatically loaded floating wear plates in gear pumps, Wear,209, pp. 184 192. [3]. Koc, E., 1994, Bearing misalignment effects on the hydrostatic and hydro dynamic behaviour of gears in fixed clearance end plates, Wear,173, pp. 199206. [4]. Koc, E., 1991, An investigation into the performance of hydrostatically loaded end-plates in high pressure pumps and motors: Movable plate design, Wear,141, pp. 249265.
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[5]. Foster, K., Taylor, R., and Bidhendi, I. M., 1985, Computer prediction of cyclic excitation sources for an external gear pump, Proc. Inst. Mech. Eng., Part C: Mech. Eng. Sci.,199, No. B3, pp. 175180. [6]. Chen, C. K., and Yang, S. C., 2000, Geometric modeling for cylindrical and helical gear pumps with circular arc teeth, Proc. Inst. Mech. Eng., Part C: J. Mech. Eng. Sci.,214, pp. 599 607. [7]. Mitome, K., and Seki, K., 1983, A new continuous contact low-noise gear pump, Journal of Mechanisms, Transmission and Automation in Design,105, pp. 736 741. [8]. Manring, N. D., 2000, The discharge flow ripple of an axial-piston swash-plate type hydrostatic pump, ASME J. Dyn. Syst., Meas., Control,122, pp. 263268. [9]. Kalpakjian S. and Schmid, S.R. (2008). Manufacturing Processes for Engineering Materials. (5th ed., p. 1). NJ , USA: Pearson Education, Inc. [10]. Groover M.P. (2010). Fundamentals of Modern Manufacturing (Materials, Processes and Systems). (4th ed., pp. 225-227, 510-513, 604-605, 618, 541-542). USA: John Wiley and Sons, Inc. [11]. Yadav, S. K. (2010). To design, fabrication and testing of gear pump test rig. Project Report, Galgotias College of Engineering and Technology, Mechanical Engineering. [12]. Gear Pump, Bearings, Gears, Drive Shaft. (May 22nd, 2012 .). Retrieved from Wikipedia: http://www.wikipedia.com.
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