Journal of Polymer and Composites
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Optimized Design and Simulation of a Versatile Power
Transmission System for Multi-Functional Machine Tools
Ashwini Kumar Baluguri1, Srinivasa Rao Seeram2*
1
2
Department of Mechanical Engineering, KLEF University, India
Department of Mechanical Engineering, KLEF University, India
Abstract
Modern manufacturing environments demand machine tools that can efficiently handle diverse machining
tasks, making adaptable power transmission systems critical. This paper presents the optimized design and
simulation of a versatile power transmission system tailored for multi-functional machine tools. The
proposed system integrates advanced mechanical design principles with dynamic simulation to achieve
flexibility and reliability across various operational modes. Key features include optimized gear
mechanisms, variable speed control, and torque distribution tailored to specific machining requirements.
Through simulation, the system's performance is evaluated in terms of efficiency, power loss, and response
to variable loads. The results demonstrate improved energy utilization, reduced mechanical wear, and
enhanced system longevity, making the design ideal for multi-functional applications. This work
contributes to advancing machine tool performance and supporting complex machining operations in
smart manufacturing environments.
Keywords: Power Transmission System, Machine Tools, Optimized Design, Simulation, Multi-Functional.
*Author for Correspondence E-mail: ssrao@kluniversity.in, Tel: 8106330116
INTRODUCTION:
Enterprises are primarily focused on producing valuable goods at low production, machinery, and
inventory costs. However, performing multiple operations on a workpiece requires different
machines, which demands significant investment and expenditure. Small-scale industries often face
challenges in affording the large sums needed for machinery. As a result, industries aim to maximize
productivity while maintaining product quality and standards at minimal costs. With technological
advancements, processes have become faster and more efficient, but this also calls for substantial
investments. A versatile machine tool can perform various operations, but some tasks must be
completed at different working points. Modern machines eliminate this issue by allowing
simultaneous operations. This project aims to design a power transmission system using gears for a
combined machine tool running on a single power source. Power transmission facilitates the transfer
of energy from its generation point to where it is needed to perform work. In this system, gear drives
are used. Gears are mechanical components that transmit rotational force to another gear or device. In
this project, both spur gears and bevel gears are utilized for power transmission, and clutches are
employed to engage and disengage power transmission between the driving and driven shafts.
LITERATURE SURVEY:
Before beginning our project, we reviewed numerous journals and papers on multipurpose machine
tools. By examining the nomenclature and relevant details, we gathered information that would aid in
designing gears for this tool. We utilized formulas from various papers and referenced the PSG
databook for certain gear values.
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Fig. 1: Transmission of power
Heinrich Arnold (November 2001) noted that innovation in the machine tool industry has traditionally
been seen as slow, with long development cycles of about 15 years. However, recent history reveals
that the integration of digital controls and computers has triggered three waves of technological
disruption, which many companies initially underestimated. This article provides an overview of the
machine tool industry's history since the introduction of numerical controls, highlighting the
disruptive nature of this technology.
Around 100 interviews were conducted with industry leaders and experts who have witnessed the
industry's progress over the past four decades [1]. Dr. Toshimichi Moriwaki studied recent trends in
machine tool technologies, focusing on high-speed and high-performance tools, multi-functional
machines, ultra-precision instruments, and advanced control technologies [2]. Frankfurt-am Main
emphasized that selling machine tools in today's market is highly challenging. Modern tools must be
highly versatile, capable of working with a wide range of materials, minimizing waste, and adapting
to new job requirements [3].
Rakesh S. Ambade, Komal D. Kotrange, and others, in their work on "Paddle Operated Multipurpose
Machine," reviewed human-powered machines. Dharma Chaitanya Kirtikumar developed a
multipurpose machine that operates without electricity for tasks like cutting and drilling, using a chain
drive powered by human effort. However, the machine can also function with electric power if
needed. This design is particularly suitable for developing regions, as it does not rely on electricity
and can be built using a metal frame, pulleys, rubber belts, chains, grinding wheels, saws, and a foot
pedal for manual operation [4].
FUNCTIONS PERFORMED BY THE MULTI-FUNCTIONAL MACHINE:
Lathe Machine: A lathe is a machine that rotates a workpiece around an axis to perform various tasks
such as cutting, sanding, knurling, drilling, deformation, facing, and turning [5]. Tools are applied to
the workpiece to create a symmetrical product around the axis.
Drilling Machine: Drilling is a metal-cutting process performed using a rotating tool to create circular
holes, often threaded, in solid materials. Additional operations like reaming, boring, counterboring,
countersinking, spot facing, and tapping can also be done with this machine [6].
Milling Machine: A milling machine is used to remove metal and shape a workpiece into the desired
form by using a rotating cutter called a milling cutter. Operations such as angular milling, face
milling, saw milling, side milling, form milling, profile milling, and straddle milling can be performed
on this machine [7].
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Fig. 2: Multifunctional Machinery
Fig. 2 shows the multi-functional machinery.
System of the equipment for transmitting power:







The entire system operates using a single DC shunt motor, as it maintains a consistent speed
as shown in Fig. 1.
When the machine is powered on, we must select which tools need to operate [8].
This multipurpose machine allows two tools to run simultaneously, either for turning and
milling operations or for drilling and milling tasks at the same time [9].
There is a mechanism to engage and disengage the power transmission shaft from the
machine and other shafts [10].
In this multipurpose machine, power transmission is achieved using spur gears, bevel gears,
shafts, and a clutch. Spur gears are chosen for their higher efficiency due to full tooth contact
[11].
Bevel gears are used to transmit power between vertical and horizontal directions, or the
reverse, based on the positioning of the gears [12].
A 1500 RPM, 2HP DC shunt motor is used in this multipurpose machine, providing the
required speed for the tools, accounting for minimal power losses during operation [13].
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Fig. 3: System of power transmission
Fig. 4: An isometric perspective of power transmission system
Figures 3 & 4 depicts the system of power transmission.
Lathe speeds:
Table 1: Different speeds of lathe
Operation
m/min
Dia of tool(mm)
Rpm range
Turning
25-31
15.9
500-620
Thread cutting
9-10
15.9
180-200
Drilling
28-35
15.9
560-700
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Milling:
Table 2: Different speeds in milling
Operation
SFPM
range
Dia of
tool(inch)
Rpm range
Side milling
30-45
1’’
120-180
Face milling
40-50
1’’
160-200
Plain milling
30-45
1’’
120-180
Form milling
30-45
1’’
120-180
Drilling:
Table 3: Different speeds in drilling
Rpm range
50-150
20-30
15-25
Dia of
tool
0.5’’
0.5’’
0.5’’
30-40
0.5’’
240-320
Operation
SFM
Drilling
Reaming
Tapping
Screw
cutting
400-1200
160-240
120-200
Tables 1,2,3 gives the information of different speeds and their rpm ranges in turning, milling
and drilling operations.
ANALYSIS:
After finishing the model in Solid Works, the file is saved in the igs format. We have
considered both bevel and spur gears independently for the analysis (Figures 5, 6). The
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analysis is completed in Ansys, and the gears are in IGS format. The gears are the subject of
the static structural analysis. The geometry is used to import the model into Ansys, and
following that, the gears receive all the parameters, including material and details. by using
mesh with fine element size and concentric gears. By providing frictional support to gear 1
first, then fixed support to gear 2, then momentum to gear 1 at the necessary range.
calculating the equivalent stress, maximum principle stress, and total deformation by solving
the model (Fig. 7).
Fig. 5: Spur gear
Fig. 6: Analysis of spur gear
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Fig.7: Distortion in spur gear
ACKNOWLEDGMENTS:
I would like to express my sincere appreciation to my Supervisor, Dr. S.S. Rao, for his invaluable
guidance and support throughout this research project. His expertise, insightful feedback, and
encouragement have been instrumental in shaping the direction and quality of this work. I am also
grateful to the Head of the Department of Mechanical Engineering, Dr. T. Vijaya Kumar, for his
support and for providing a conducive research environment. Additionally, I would like to thank the
faculty members of the Mechanical Engineering Department for their valuable insights and
suggestions. Their collective expertise has greatly enriched my understanding of the subject matter.
ADVANTAGES:
• The machines rely on carefully designed structures that allow the customer to efficiently transition
from one capacity to the next.
• The machine device's main purpose is to accomplish two or more tasks simultaneously, which saves
time and maintains control.
• To save power, we have just used one engine in this project to power the transmission system.
• We used apparatuses in this power transmission framework, which allows for a significant range of
speed and torque for comparable information control.
• Planning with greater precision, less grinding hardship, and quieter activity performance are all
possible when using apparatuses.
• Saving space is essential for the development of these machines.
• Although mix machines can be highly expensive, there is typically a cost savings over individual
machines of the same grade. A blend machine takes up a lot less room than equivalent separate
machines.
• The ability to use several cutting tools in machining centers to carry out various unique operations
on a single machine equipment.
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FUTURE SCOPE:
1. The rigging framework's mechanization in machine instruments may facilitate work and reduce
labour in the workshop.
2. The machine equipment can be made more and more convenient, requiring less workspace and easy
maintenance.
3. It could be feasible to use a single engine to transmit capacity to all three instruments
simultaneously.
Modifications to the configuration can achieve the desired machine speed for material handling.
CONCLUSION:
For this multifunctional machine equipment, we have designed a power transmission architecture that
allows us to simultaneously do two tasks: drilling and processing, or machine and processing. A
single engine provides power to the machine that houses many instruments for material handling,
hence reducing power consumption. Additionally, because the entire framework's rigging is contained
in a single box, it reduces machine workspace. Depending on the duties being performed
simultaneously, the two instruments' paces may be the same or different. Utilizing the computer to do
two activities at once will save time. It also increases profitability.
REFERENCES:
1. J.O. Nordiana, S.O. Ogbeide, N.N. Ehigiamusoe and F.I. Anyasi., 2007, “Computer aided design of
a spur gear.” Journal of Engineering and Applied Sciences 2 (12); pp 17431747.
2. Darle W. Dudley, 1954, Hand book of practical gear design
3. Alec strokes,1970, High performance of gears design
4. Maitra. G.M, 2004, Hand book of Gear Design, Tata Mc Graw Hill, New Delhi.
5. s. Md. Jalaluddin, 2006,” Machine Design.” Anuradha publications, Chennai.
6. Thirupathi Chandrupatla, Ashok D. Belegundu,” Introduction to finite element in Engineering”
2003
7. PSG,2008.” Design data,”Kalaikathir Achachagam publications, Coimbatore, India.
8. S. Mahalingam, R.E.D Bishop,1974,”Dynamic loading of Gear Tooth”, Journal of sound and
vibrations,36(2).pp179189
9. M. Santhanakrishnan and N. Mani Selvam, “Design and Fabrication of Six Speed Constant Mesh
Gear Box,” in International Journal of Engineering Research &Technology, vol. 3, no. 9, pp. 662-666,
September 2014. [2]
10. R. V. Mulik, S. S. Ramdasi and N.V. Marathe, “Dynamic Simulation of 6 Speed Gearbox of
Tipper Application to Improve Gear Contact Life,” in Symposium on International Automotive
Technology 2017. [3]
11. A. Dhawad, D. Moghe, G. Susheel and G. Bhagat, “Design of a Multispeed Multistage Gearbox,”
in Int. Journal of Engineering Research and Applications, vol. 6, no. 5, pp. 54-57, May 2016.
12. Selection of Gear Ratio for Smooth Gear Shifting Jaideep Singh, k.v.v. rao Srinivasa and
Jagmindar Singh Mahindra & Mahindra Ltd., SAE International, 2012-01-2005.
13. Kapelevich, A. and McNamara, T., "Direct Gear Design® for Automotive Applications”, 2013
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