MMN LAB PROJECT REPORT
UET
DEPARTMENT OF MECHANICAL, MECHATRONICES AND
MANUFACTURING ENGINEERING (NEW CAMPUS)
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Submitted by:
[Link] Registration No. Name
1 2024-ME-303 Muhammad Umar
2 2024-ME-311 Abdullah Tabish
3 2024-ME-312 Ahmad Mubashar Dar
4 2024-ME-323 Usman Saif
5 2024-ME-325 Mehroz Moazam
6 2024-ME-329 Ahmad Farooq
7 2024-ME-332 Zain Khalid
8 2024-ME-333 Muhammad Huzaifa Rehman
9 2024-ME-347 Ammar Ahmad
10 2024-ME-348 Rehan Ahmad
Submitted To:
[Link] Nawaz
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Manufacturing of Spur Gear Using Conventional, Non-
Conventional Processes
Introduction:
Spur gears are one of the most widely used mechanical components for power and torque transmission in
engineering applications. They are commonly found in washing machines, blenders, clothes dryers, construction
equipment, fuel pumps, and mills. Due to their straight teeth and parallel shaft arrangement, spur gears offer
simplicity in design, ease of manufacturing, and high efficiency. This lab report documents the design
considerations, manufacturing processes, and justification of selected machining techniques for producing a spur
gear as specified in the given engineering activity.
Objective
The objectives of this laboratory work are:
• To study spur gear geometry and specifications.
• To identify all possible conventional and non-conventional machining processes applicable for gear
manufacturing.
• To justify the selection of specific machining processes.
• To manufacture a spur gear using at least one conventional machining process, one non-conventional machining
process, and one abrasive process.
Given Gear Specifications
The spur gear to be manufactured has the following specifications:
• Type of Gear: Spur Gear
• Working Depth: 10 mm
• Circular Diameter: 150 mm
• Number of Teeth: 19
• Pitch: 6 mm
• Inner (Bore) Diameter: 75 mm
Material Selection
Medium carbon steel is commonly used for spur gears due to its good strength, machinability, and wear
resistance. Other materials such as alloy steel, cast iron, or brass can also be used depending on application
requirements.
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Conventional Machining Processes
Conventional machining processes rely on direct mechanical contact between the cutting tool and the workpiece.
Turning
Turning is used to machine the outer diameter and inner bore of the gear blank on a lathe machine. This
process ensures dimensional accuracy and concentricity.
Milling
Gear teeth can be cut using a milling machine with a form cutter or involute cutter. Indexing is used to
divide the gear blank into equal tooth spaces.
Hobbing
Gear hobbing is a highly productive conventional method used for cutting spur gears. It provides accurate
tooth profile and good surface finish.
Non-Conventional Machining Processes
Non-conventional machining processes are used when conventional methods are difficult or uneconomical.
Electrical Discharge Machining (EDM)
EDM is suitable for producing complex gear profiles in hard materials. It uses electrical sparks to remove
material without physical contact.
Laser Beam Machining (LBM)
Laser cutting can be used for gear profiling with high precision and minimal mechanical stress.
Water Jet Machining (WJM)
High-pressure water mixed with abrasives can cut gear blanks without generating heat-affected zones.
Abrasive Machining Processes
Abrasive processes improve surface finish and dimensional accuracy.
Gear Grinding
Gear grinding is used as a finishing operation to achieve precise tooth geometry and smooth surface
finish.
Honing and Lapping
These processes are used to further enhance surface quality and reduce noise during gear operation.
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Process Selection and Justification
For this lab activity:
• Turning is selected as the conventional process for preparing the gear blank.
• EDM is selected as the non-conventional process for accurate tooth profile generation.
• Gear grinding is selected as the abrasive process to improve surface finish and accuracy.
This combination ensures dimensional accuracy, good surface finish, and efficient manufacturing.
Manufacturing Procedure
1. Raw material preparation and facing.
2. Turning of outer diameter and inner bore.
3. Tooth cutting using selected process.
4. Finishing using grinding.
5. Inspection and quality control.
Aim
The aim of this experiment is to manufacture a spur gear with given specifications using conventional, non-
conventional, and abrasive machining processes, and to understand the selection and justification of each process
involved in gear manufacturing.
Apparatus and Equipment Used
The following machines, tools, and equipment are used in the manufacturing of the spur gear:
• Lathe machine
• Milling machine / Gear hobbing machine
• EDM machine (non-conventional process)
• Gear grinding machine
• Indexing head
• Cutting tools and gear cutters
• Measuring instruments (vernier caliper, micrometer, gear tooth vernier)
• Safety equipment (gloves, goggles, apron)
Applications
The manufactured spur gear can be used in household appliances, industrial machinery, and automotive systems.
Result
The spur gear was successfully manufactured according to the given specifications. The gear achieved acceptable
dimensional accuracy, proper tooth profile, and good surface finish. The use of conventional, non-conventional,
and abrasive machining processes demonstrated the importance of process selection in achieving high-quality
gear components.