Powerauto GEAR PUMP - HD-Report PDF

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POWERAUTO GEAR PUMP

[17/10/2020]

UTS Authored by: [xxx]

Index Introduction................................................................................................................5 Description of Target and its Application.................................................................5 Analysis of Components..........................................................................................6 Introduction.........................................................................................................6 How does a Gear Pump Function?.......................................................................6 Main Parts of the Gear Pump Explained & Shown:..............................................7 Diagrams.................................................................................................................9 ..................................................................................................................................10 ..................................................................................................................................11 ..................................................................................................................................12 ..................................................................................................................................13 ..................................................................................................................................13 Materials...................................................................................................................14 Material Specification............................................................................................14 Strength.............................................................................................................14 Weight...............................................................................................................14 Wear Resistant...................................................................................................14 Thermal Resistant..............................................................................................14 Cost-Effectiveness..............................................................................................14 Consideration Point...........................................................................................14 Material Used........................................................................................................15 Spheroidal Graphite Iron....................................................................................15 D2 Steel.............................................................................................................15 Steel Alloy..........................................................................................................15 Grey Cast Iron....................................................................................................16 ..........................................................................................................................16 2 xxx UTS Major Project

Manufacturing...........................................................................................................17 Proposed Manufacturing Process-Sand Casting.....................................................17 ..............................................................................................................................18 ..............................................................................................................................18 Required Manufacturing Equipment......................................................................18 Detailed Description of Process.............................................................................19 Advantages & Disadvantages of Sand Casting........................................................20 Proposed Manufacturing Process-Machining.........................................................21 Milling Machine.................................................................................................21 Lathe Machine...................................................................................................22 Drill Press...........................................................................................................22 Detailed Description of Process.............................................................................23 Manufacturing the Drive gear............................................................................23 Manufacturing the Drive Gear – Material Wastage............................................25 Manufacturing the Thrust Plate.........................................................................25 Manufacturing the Main Body...........................................................................25 Manufacturing the Pump Head..........................................................................27 Alternatives of Manufacturing Process – Drilling, Tapping and Cutting Operations 28 Drilling & Tapping..............................................................................................28 Cutting Operation..............................................................................................28 Advantages & Disadvantages Milling Over Drilling & Tapping................................28 Quality Assurance & Inspection.................................................................................29 Estimation of Manufacturing Cost.............................................................................30 References.................................................................................................................31 Pictures and Diagrams...........................................................................................31 Knowledge.............................................................................................................32 My Own source.....................................................................................................32 3 xxx UTS Major Project

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Introduction Description of Target and its Application

Intake Port The Intake Port is the port that deposits the fuel and air mixture into the crankcase for it to then be transferred via the transfer port to the cylinder for combus)on. It usually consists of a valve that allows for periodic opening and closing of the port throughout the strokes. Exhaust Port 5 xxx UTS Major Project

The Exhaust Port is the port that deposits the burnt and post-combus)on gases out of the cylinder and out through the exhaust. It consists of a run o4 pipe leading to the exhaust, and the gasses escape through the pipe a0er the combus)on has occurred. Crankcase The Crankcase protects the cranksha0 and contains the fuel air mixture a0er it is deposited from the intake port. It is also where the counter weight is 6 xxx UTS Major Project

protected along with the crank pins and journal.

Juscaon of Required Accuracy and Surface Integrity The overall rendering of the engine block is unique to the various components and features. The externals of the engine block do not require such precision as they are mainly sta)c or have minimal 7 xxx UTS Major Project

movement against surrounding parts, as the engine block is sta)onary on the lawn mower, with only vibra)ons being the dynamics it undertakes. However there are places where accuracy is paramount. This is because moving parts usually require certain 6nishes of low fric)on depending on applica)on and also certain 6nishes for the sealing of components. These places include the connec)on plate with the cylinder, where it bolts on, 8 xxx UTS Major Project

the internal cylinder wall where the piston moves and the diameter of the crank sha0 housing. Machining methods of achieving the required accuracy and surface 6nishes include honing, lapping and super 6nishing. Although high precision and accuracy is typically needed for moving parts, joining of parts usually requires precision as both parts need to be able to 6t well. For example, the joining of the cylinder 9 xxx UTS Major Project

head to the engine block must be accurate as the 1cm join screws, as seen in Figures 1, undergo tensile stress as combus)on within the cylinder adds forces pushing against the walls of the combus)on chamber, as well as vibra)ons from the rpms. It is also important to have the walls and edges of the cylinder alignments between the cylinder head component and the engine block, as 10 xxx UTS Major Project

movement of the piston can be disrupted if misaligned. Also the joining between the crankcase housing and external engine block mount as seen in Figures 1 also require alignment accuracy for the parts to join, where surface 6nishes between joints should be smooth for 6tment accuracy. It is also important to note that a9en)on to the thickness of joining screws and threads should allow for 11 xxx UTS Major Project

the shear stresses ac)ng on the screws from component vibra)on when engine is running. Gear pump is one of the most common used engineering applications today that enabling from pumping fluids with quite amount of pressure. The earliest design of gear pump was invented by a German scientist around 1600. Kepler input the idea of the rotation and classical mechanics to bring this invention to the world. This marvelous invention has main purpose within chemical installations to pump high viscosity fluids. The gear pump divided into two piece of art variation: external gear pump and the internal gear pump. Each has unique feature for many unique purposes within different applications. The main idea of a gear pump uses the meshing of gears to pump fluid by displacement. The main purpose of using a gear pump is the hydraulic fluid power applications. The hydraulic power application with in commercial and domestic enables with little input to extensive output such as: movement and rotation. These concepts are inputted with in vehicles, machineries, aircraft, mechanical tools, and pump stations.

As the project report deeply explores the main features and properties of the gear pump, it will be understood why this invention was marvelous. The report follows on by the material and the manufacturing process of the gear pump and further details.

Figure 1.1 The power of gear pump within industries

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Figure 1.2 A modern gear pump design

Analysis of Components Introduction Gear pump a positive displacement (PD) pump, moving high viscosity fluids rapidly within an enclosed and fix passage using interlocking cogs or gears. It is flowless along the gear speed rotations and the movement of the fluid to function that the system requires. The gear pump consisting features such as: the mounting flange, driver gear, driven gear, seal, bushing, drive shaft, suction port, pressure port and case seal. For the gear pump to be impactful within a system it requires that all the components to be well combined and assembled. How does a Gear Pump Function? There are two different type of gear pump the external gear pump and the internal gear pump, according to the report abstract, the main objective is the POWERAUTO gear pump. As the gear starts to function meaning that they rotate, they separate the intake portion of the pump, creating a void and a suction, that is filled by the high viscosity fluid. As the fluid is sucked by the gears from the suction port to the discharge side of the pump, the meshing of the gears displaces the fluid. This process of the rotation of gears causes the mechanical movement within fluid, this can be considered conservation of energy and newton’s 3rd law of motion. Justification of required accuracy and surface integrity The smoother surface for the gears, drive shaft and the seal placement the better for the mechanical movements and mainly the fluid displacement. It is important to consider that the outer surface does not matter as much as the interior for the surface finishing since the time taken for the machining is quite a bit of hassle and skill. Also, outer part of the mounting flange for the joinery must be surface finished to the acquired level for better fit and assembly by the weld and fasteners, therefore machinery and surface finishing must be done after casting.

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Figure 1.4 Surface finishing of a gear Ref:1.4

Main Parts of the Gear Pump Explained & Shown: Figure 1.3 The direction of gear pump rotation during its function Mounting Flange Ref:1.3 This is the main body that tightly places on both side of the gear pump, it is mainly for holding the interior part together. It protects the gear and shaft from any exterior vibration and damages. Drive Gear The drive gear is a gear part, that causes the positive displacement of the fluid meaning that for every revolution there will be fluid displacement across the journey. Driven Gear The driven gear is also another gear part, that turns with the driver gear at the same time, in order to create pressure within the gear pump as the fluid is displaced across the ports. Seal A special rubber used to maintain the correct attachment of the gear pump and helps to improve the rotation of the drive shaft within the process. Bushing A spacer component used with in the gear pump to efficiently eliminate the collision between both driven and the driver gear at the same time during the rotation. Drive Shaf An exterior component is attached to the drive shaft that causes the rotation with in the pump, the drive shaft acts as mechanical component that transmits the torque and the rotation to the gears, but directly to the drive gear along to the driven gear.

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Figure 1.5 The make up composition of a gear pump disassembled Ref:1.5

The Intake Port is the port that deposits the fuel and air mixture into the crankcase for it to then be transferred via the transfer port to the

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cylinder for combus)on. It usually consists of a valve that allows for periodic opening and closing of the port throughout the strokes. Suction Port This is the entering point, where the fluid sucked and pushed into the gear pump during the process of the gear pump in action. Pressure Port This is the exiting point, meaning that extra pressure from the gear pump by the fluid is eliminated during the process. Case Seal A special rubber that helps the eliminate licking and stabilizing the gear pump to keep the fluid in during the process of gear rotation.

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Figure 1.6 Complete diagram of a gear pump Ref:1.6

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Diagrams

Figure 1.7 The gear head (Original Drawing) Ref:1.7

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Figure 1.8 The drive shaft (Original Drawing) Ref:1.8

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Figure 1.9 The main body (Original Drawing) Ref:1.9

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Figure 1.10 The thrust plate (Original Drawing) Ref:1.10

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Figure 1.11 The complete assembly of a gear pump (Original Drawing) Ref:1.11

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Materials Material Specification In order for the gear pump to be manufactured, certain materials with unique features and properties are needed to be considered and must meet the specifications: Strength With the gear pump during the use process high pressure is produced in order for the fluid displacement to occur or even the mobility and the action that gear pump takes place in any sort of application and more importantly to function continuously; by common sense the gear pump must be made out of high strength material that keeps stability and balance between the drive shaft and gear also the mounting flange. Weight The use of the gear pump within mechanical tools and vehicles, the manufacturing material must be light to be easily carried around or be easily transportable across sites for long duration of time. Wear Resistant Due to the extensive use of the gear pump aligned with the harsh environment and neglection and vibration the material must withstand wear and chip damage for a long period of time along lubrication and must be cleaned from dust and dirt. Thermal Resistant During the positive mesh or the fluid displacement high thermal energy is built within the case also the drive shaft. This means that the material can start to change shape if it is no manufactured out of the correct material. This can lead to malfunctioning of the product. For the lifetime of the gear pump and the product thermal resistance must be considered. Cost-Effectiveness There are billions people out there in worldwide that are economical disadvantaged and mostly below average incomers, the idea of cost effectiveness must be considered during the material selection further to the process of manufacturing by doing so to solve real world issues. Consideration Point It is understandable that during manufacturing the gear pump, the material chosen must be easily machinable and manipulated by hand cutting tools such as the plug tap and file. In this case since alloys are combination of metals that have many special properties, it is important to consider during choosing the correct material: it must be alloy, since they are light, strong and cheap in some cases.

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Material Used Spheroidal Graphite Iron Spheroidal Graphite Iron, also known as Ductile iron due to its property and the graphite structure. One of the greatest material to be used due to its sensible advantage of being able to be die casted, allowing faster manufacturing point and saving material concluding to a good economical advantage. This material property consists of 3.2-3.6% carbon, 2.2-2.8% silicon, 0.1-0.2% manganese, 0.03-0.04% magnesium, 0.005-0.04% phosphorus, 0.005-0.02% sulfur,...