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A Project Report On
DESIGN AND FABRICATION OF POWDER METAL REINFORCED COMPOSITE

MATERIAL SPUR GEAR UNDER STATIC ANS DYNAMIC LOADING CONDITION
A Dissertation Submitted in Partial Fulfillment of the Requirements for the Award of the Degree of
MASTER OF TECHNOLOGY
In
MECHANICAL ENGINEERING (ADVANCED MANUFACTURIN GSYSTEMS)

By
CHELLURI JAYARAM Roll No: 206T1D1701

Under the supervision of
Mr. KOTIKA SOMARAJU

Assistant Professor
Department of Mechanical Engineering
DEPARTMENT OF MECHANICAL ENGINEERING

PYDAH COLLEGE OF ENGINEERING
(Approved by AICTE, New Delhi & Affiliated to JNTUK, Kakinada )
Yanam Road, Patavala, Kakinada-533461, E.G.Dt
2020-2022
DEPARTMENT OF MECHANICAL ENGINEERING
PYDAH COLLEGE OF ENGINEERING
(Approved by AICTE, New Delhi & Affiliated to JNTUK, Kakinada )
Yanam Road, Patavala, Kakinada -533461, E.G.Dt
CERTIFICATE
This is to certify that the thesis entitled “DESIGN AND FABRICATION OF POWDER METAL
REINFORCED COMPOSITE MATERIAL SPUR GEAR UNDER STATIC ANS DYNAMIC
LOADING CONDITION ” submitted by Mr. CHELLURI JAYARAM bearing Reg. No. 206T1D1701
of final year M.Tech (Mechanical Engineering) in partial fulfillment of the requirement for the award of
degree of MASTER OF TECHNOLOGY in ADVANCED MANUFACTURING SYSTEMS from
University College of Engineering (Autonomous), JNTU Kakinada. This report is an authentic work carried out by
him under my supervision and guidance at Pydah College of engineering, during the academic year 2020-2022 and
it is suitable for acceptance according to the requirement of the university.
Project Guide Head of the Department
Mr. KOTIKASOMARAJU Mr.KOTIKASOMARAJU

Assistant Professor Assistant professor
EXTERNALEXAMINER
ACKNOWLEDGEMENT
The satisfaction that accompanies successful completion of any task would be in

complete with out the mention people who made it possible and whose constant supervision and
encouragement crown all the efforts with success. The acknowledgement transcends the reality
of formality.
I am thankful to my beloved supervisor Mr. KOTIKA SOMARAJU ,Assistant

Professor, who has spared his valuable time and append novel ideas to guide me in limelight. I
am indebted to him without whom I may not have culminated to principal of the project.
I also wish to convey my sincere thanks to Mr. KOTIKA SOMARAJU Assistant

professor, Head of the Mechanical Engineering Department who provided vital information
which was necessary for the project.
I thank full to Dr.P.V.Surya Prakash, Ph.D, Principal of Pydah College of Engineering

for providing appropriate environmental required for this project.
I also thankful to all staff members, lab Assistants, librarians, parents and friends who are
directly and indirectly helped us in the completion of the project with flying colors
CHELLURI JAYARAM
Roll No:206T1D1701
DECLARATION
I here by declare that this project titled as “DESIGN AND FABRICATION OF

POWDER METAL REINFORCED COMPOSITE MATERIAL SPUR GEAR
UNDER STATIC ANS DYNAMIC LOADING CONDITION ”, has been under
taken at and this work is submitted to PYDAH COLLEGE OF ENGINEERING ,Patavala,
Affiliated to JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY, Kakinad in
partial Fulfillment of the Degree of Master of Technology.
I further declare that this project work has not been submitted in full or part or
the award of any other Degree in this or any other educational institutions.
Place: Patavala CHELLURI JAYARAM
Date: Roll no: 206T1D1701

INDEX
ABSTRACT 1
CHAPTER1 2
1.INTRODUCTION 2
1.1 BACKGROUND AND MOTIVATION 2

1.2 COMPOSITE MATERIALS 2
1.3 TYPES OF COMPOSITES 3
1.4 EPOXY RESIN 6
1.5 CAST IRON POWDER 8
9
1.5.1 CAST IRON POWDER SPECIFICATIONS
1.6 INTRODUCTION TO RESEARCH TOPIC 10

CHAPTER 2 11
2. LITERATURE REVIEW 11
CHAPTER 3
3. MATERIALS AND METHODS 17
3.1 MATERIALS 17
3.2 COMPOSITE FABRICATION 20
3.3 MOULD PREPARATION 21
3.4 MECHANICAL PROPERTIES 22
3.5 GEAR MAKING 25

3.6 GEAR TEETH TEST 25
CHAPTER 4 26
4.1 DESIGN 26
RESULTS AND DISCUSSION 28
CONCLUSION 35
REFERENCES 36
JOURNAL 46
CERTIFICATES 56
PLAGIARISM 58
LIST OF FIGURES
Fig-1.1: Classification of composites based on reinforcement type.

Fig-1.2: continuous fiber and discontinuous fiber
Fig-1.3: Reinforcement of particles
Fig-1.4: Epoxy resign and Hardener.
Fig-1.5: Vacuum sealed Cast iron metal powder.
Fig-3.1: Epoxy resigns
Fig-3.2: Cast iron powder
Fig-3.3: During sedimentation of solution
Fig-3.4: Mould for tensile and bending test
Fig-3.5: mould for compression hardness and microstructure.
Fig-.3.6: solidified specimens
Fig-3.7.: Similar specimens are prepared according ASTM standards with variation of heights
for compression and hardness test.
Fig-3.8: Similar specimens are prepared according ASTM standards for bending and tensile test.
Fig-3.9: specimens for tensile test after finishing
Fig-:3.10 Specimen made up of 45% CI composite
Fig-3.11: Gear tooth Bending Test
Fig-3.12: Runout checkin
Fig-5.1: Tested specimens
LIST OF TABLES
Table-1.1: Physical Properties of cast iron power
Table 3.1: provides some of the important properties of epoxy
Table 3.2: Show the properties of epoxy material.
Table 3.3: Properties of cast iron powder
Table 4.1: Material Properties of Gear Materials
Table-5.1: The values of mechanical properties of all four tests of four different compositions
DESIGN AND FABRICATION OF POWDER METAL REINFORCED
COMPOSITE MATERIAL SPUR GEAR UNDER STATIC ANS DYNAMIC
LOADING CONDITION
Abstract
Gears are the one of the most widely used components in the power
transmission system. Among them Spur gears are the one of the simplest and mostly
used. Now a days there manufacturing of gears became a challenging issue while they
are operating under various load and speeds. The gears generally fail when they
subjected to impact loads above their operating limits. Therefore, it is essential to
manufacture a gear with alternate materials and methods which can withstand various
conditions. Composite material can fulfil the requirements needed for gear
manufacturing and best alternate for gears made up of metals.
In this thesis metallic spur gear is replaced with composite material gears
which have better strength to weight ratio, good bending strength and increase the life
of the gear. Powder metal reinforced metal composite is used as the replacement of
metal gears.
Solid work is used for modelling of the spur gear and FEM analysis is done by
ANSYS V14.0. Composite gears offer better mechanical properties over steel alloys.
Powder metal reinforced metal matrix composite specimens are prepared
according to ASTM standards to evaluate the mechanical properties and spur gear is
prepared with the same composite material and tested static load and dynamic loading
condition. Cast iron powder as reinforcing material and epoxy resin is matrix material
with appropriate weight percentage.
Keywords: Composite material, epoxy resin, cast iron powder, spur gear, modelling,
testing and evaluation of mechanical properties.
1
Chapter-1
INTRODUCTION
1.1. Background and Motivation:
To achieve this, the most obvious approach would be to apply thicker layers of
readily available thermal insulation materials. But this can locally result in the use of
undesirable thick constructions and related changes in building methods, not to
mention the loss of valuable floor space and the related higher costs. Instead of this
option, novel types of affordable and process able thermal insulation materials with
improved efficiencies are being considered. Among the best thermal insulation
materials available today are vacuum insulation panels and aero gel-based materials.
The low thermal conductivities of these materials originate from having a reduced gas
phase conductivity based on vacuum and on pore sizes of below 100 nm. But in spite
of their high thermal insulation efficiencies, these materials suffer from process ability
and pricing issues that restrict their wide spread utilization.
1.2. Composite Materials:
Composites are combinations of two or more materials in which one or more

of the materials, called the reinforcing phase, are in the form of fibers or particles and
are embedded in the base material called the matrix phase. The primary functions of
the matrix are to transfer stresses between the reinforcing fibers/particles and to
protect them from mechanical and/or environmental damage whereas the presence of
fibers/particles in a composite improves its mechanical properties such as strength,
stiffness etc. A composite is therefore a synergistic combination of two or more
constituents that differ in physical form and chemical composition and which are
insoluble in each other. The objective is to take advantage of the superior properties
of both materials without compromising on the weakness of either. Composites have
successfully substituted the traditional materials in several light weight and high
strength applications. The reasons why composites are selected for such applications
are mainly their high strength-to-weight ratio, high tensile strength at elevated
temperatures, high creep resistance and toughness. Typically, in a composite, the
reinforcing materials with low densities are strong while the matrix is usually a
ductile or tough material. If the composite is designed and fabricated correctly it
combines the strength of the reinforcement with the toughness of the matrix to

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A Project Report On

DESIGN AND FABRICATION OF POWDER METAL REINFORCED COMPOSITE

MECHANICAL ENGINEERING (ADVANCED MANUFACTURIN GSYSTEMS)

CHELLURI JAYARAM Roll No: 206T1D1701

Mr. KOTIKA SOMARAJU

DEPARTMENT OF MECHANICAL ENGINEERING

(Approved by AICTE, New Delhi & Affiliated to JNTUK, Kakinada )

Yanam Road, Patavala, Kakinada -533461, E.G.Dt

Project Guide Head of the Department

Mr. KOTIKASOMARAJU Mr.KOTIKASOMARAJU

The satisfaction that accompanies successful completion of any task would be in

I am thankful to my beloved supervisor Mr. KOTIKA SOMARAJU ,Assistant

I also wish to convey my sincere thanks to Mr. KOTIKA SOMARAJU Assistant

I thank full to Dr.P.V.Surya Prakash, Ph.D, Principal of Pydah College of Engineering

I here by declare that this project titled as “DESIGN AND FABRICATION OF

Place: Patavala CHELLURI JAYARAM

Date: Roll no: 206T1D1701

1.1 BACKGROUND AND MOTIVATION 2

1.6 INTRODUCTION TO RESEARCH TOPIC 10

3.4 MECHANICAL PROPERTIES 22

3.5 GEAR MAKING 25

Fig-1.1: Classification of composites based on reinforcement type.

1.2. Composite Materials:

Composites are combinations of two or more materials in which one or more

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