Abstract
The objective of this work is to use advanced manufacturing process i.e. Direct Metal Laser Sintering (DMLS) to produce complex design component such as spur gear. In this view, spur gear of gear box of vehicle model TATA super ACE mint is considered. 3D modeling of the spur gear is done using Solidworks software by considering the design parameters of the spur gear. Design calculations of Spur gear are done as per Lewis equation and Castigliano’s equation analytically. Finite Element analysis software ANSYS is used to study the equivalent von mises stress and the total deformation developed in the spur gear for the given torque and compare with the analytical results. In this study spur gear is manufactured using DMLS by using maraging steel powder. The optimized process parameters were used to manufacture the spur gear and these types of gears can be used in any power transmission system.
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