Summary
Summary
Embedded Files
I designed and built a functional planetary gear system for my Mechanical Design course. The project involved modeling each component in CAD, 3D printing the gears, laser cutting acrylic plates, and assembling the final mechanism. This hands on build demonstrated key concepts in gear design, tolerancing, and mechanical assembly while producing a working system.
Goals
Goals
The goal of this project was to design a fully functional planetary gearset with proper gear meshing while applying CAD modeling techniques to create accurate and manufacturable components. The design was then brought to life through manufacturing processes including 3D printing and laser cutting. After fabrication, the components were assembled into a complete mechanical system that operates smoothly. Ultimately, the project demonstrates how planetary gear systems can achieve multiple gear ratios through their unique configuration.
Challenges
Challenges
One of the main challenges of this project was ensuring proper tolerances so the gears could mesh smoothly without binding or slipping. Careful alignment of all components during assembly was critical to maintain consistent rotation and overall performance. I also had to account for the limitations of 3D printing and laser cutting, which required adjustments to the design to ensure accurate fabrication. Minimizing friction and unwanted play within the system added another layer of complexity. Overall, the project required translating theoretical gear design into a reliable and functional physical mechanism.
Details
Design Overview
Design Overview
A significant amount of effort went into designing the gears for this project. This was my first experience using parametric equations and more advanced mathematical concepts within CAD to define geometry. In previous projects, I relied on pre built gears from the SOLIDWORKS toolbox, but this project required building the gear profiles from the ground up, which gave me a much deeper understanding of how gears actually function.
Gear Geometry
Gear Geometry
Designing the gear required careful consideration of several key parameters that define its performance. These included the diametral pitch, pitch circle, base diameter, pressure angle, and the involute tooth profile. The base diameter determines where the involute curve begins, which is critical for proper tooth engagement. The involute curves themselves define the contact surface between gear teeth and are specifically designed to reduce friction and ensure efficient power transmission. The pitch diameter represents the effective contact circle between gears, while the addendum defines the height of the teeth above that pitch circle.
Parametric Modeling
Parametric Modeling
The involute tooth profile was created using parametric equations, allowing for precise control over the gear geometry. This approach ensured that each tooth followed the correct mathematical profile, which is essential for smooth meshing and consistent motion. Using parametric design also made it easier to adjust dimensions and refine the model without having to completely rebuild the geometry.
Manufacturing and Results
Manufacturing and Results
After completing the design in SOLIDWORKS, the gears were manufactured using 3D printing, while the supporting structure was created using laser cut acrylic. Careful attention was given to tolerancing during the design phase, which resulted in gears that meshed smoothly without binding. The final assembled mechanism operates reliably and serves as a functional demonstration piece that now sits on my desk.
Gallery
Gallery
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