The Life of a Gear

An overview of design, production and use of an inwheel compounded planetary gearset for an electric Formula Student Racecar. Formula Student is the largest engineering design competition for Students all around the world.
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[@samgorman5731]

Our formula student had an old metal flask welded in place for an oil catch ... no wonder these guys do so well.

[@VaibhavSarda]

Glad to be a mechanical engineer to understand where they DID show the machining part. Infact here's a few of the machining processes that they're shown: 0:34 Surface Grinding of Blank 0:53 Wire EDM to cut the profile (you really do get a machined gear out of that single process) They've also shown a lot of the measurement processes used nowadays, optical inspection etc.

[@IkarimTheCreature]

1:47 also shows vibratory tumbling of the gears to improve surface finish and remove burrs.

[@zhouzhou3785]

somehow let me remind the life of a bolt video from red bull racing.

[@capelli8275]

yeah, they go a lot of inspiration from that video, and it was very well made

[@overunityinventor]

This is half life, you didn't show how does the gear dies.

[@hotcroc2856]

#GearsLiveMatter

[@danishdezembro1116]

Half process...

[@FirstLast-yh5vc]

This is formula student. In the lifetime of the car these gears are unlikely to break down, but it would have been nice to see it at the end of the season :D

[@gbornitz]

@@FirstLast-yh5vc This is Formula Student. The gear is probably designed to last 1000 km to save another 2 g of weight.

[@riderscornernz8945]

Love this. I believe Red Bull did a similar one for a bolt a while ago

[@khairulasri2070]

This video should be named the life of mechanical engineer

[@alexandresousa6136]

This is so satisfying to watch .. A raw piece of still being changed por something mechanical :D

[@josehdz6154]

The grind never stops

[@bollingbollz9379]

It's amazing how far technology has come.

[@hedley326]

These videos are incredible

[@nickfrechette19]

I love technology so much.... Incredible...

[@Baard2000]

The most crucial part: tooth surface preparation by either polishing ( @Roessler) , grinding or the arc wire machining is missing. Also the eventual coating with wcc or dlc ....would be nice. If regtulations allow.

[@mrpalaces]

Mechanical engineering it's best engineering

[@nobustrive1405]

Super quality product!!

[@infaskjeeshorts5729]

just amazing!!!

[@pawelzygmunciak3680]

What is the device the engineer operates by left hand @ 0:18 ? Is it a HW part of that CAD program?

[@logicmaster55]

Excellent Video !!!

[@sitrakamatthieu]

Awesome vidéo!!! Bravo !

[@seanriopel3132]

Anyone know what controller the man was using with his left hand in the beginning?

[@ADX420]

How familiar are you with the gears wars?

[@parthapratimsamanta3982]

which software you use for cad designing purpose

[@boomperson818]

and this is where the series takes off

[@phantommedia9964]

What's the music used in this video? I like it, thanks!

[@sskorch82]

So they sent the part off to be tumbled and heat treated? I work for a company that can do everything shown in the video without sending off the part.

[@nagesh007]

Wow amazing

[@lubinlaison1216]

Which designing software do they use

[@estroncio64]

Do they use CMM for all the gears they make?

[@Crunchh]

On which software you design?

[@micromachine7954]

So each wheel has an electric motor, with a planetary gear box that the actual wheel bolts to? Is this for torque multiplication or something?

[@tarksable]

That end cars awesome. i want it now.

[@spike4850]

tarksable well just think about how much work went into making that one gear, and from that get a rough idea of how high the price would be.

[@commvaibhav1]

wow!! awesome!!

[@blinkmotorworks]

Amazing video. Deserves more likes and views

[@ariefrifqymjn]

Xade Red Bull's better

[@maxpayne438]

Xade nope, it kinda passes from blank to toothed gear in 3secs. Can't understand how they cut it and why the placed it underwater

[@brettlinton4933]

That was EDM, (Electrical discharge machining)

[@maxpayne438]

brettlinton why wasn't laser cut? And what's the machine that submerged the part?

[@ShyamUHS]

yes

[@Fruxaq]

0:19 whats program is that ?

[@SebyNeg]

Cool Video guys, very nice👍

[@dalecook1206]

So, how much exactly do you know about the gear wars?

[@ibrxhimmma8962]

i love this

[@arnaldomanggalarahardja283]

It's more precious than a diamond

[@boshypatry]

And how much does that gear cost at the end?

[@phillipmcintosh6489]

I enjoyed the video however it seemed like a lot of processes were missing from the video although I'm no gear expert. At 0:54 you see what looks like a milling machine with a fine bit that seems to drill a hole less than a mm deep and makes sparks while doing so. If this is the pre-EDM stage I would have thought the hole would need to go right through the product in order to feed the wire of the EDM machine through it and yet it didn't. Next at 0:58 you see a magic machine that you just put in a blank and out comes a finished gear. I thought it was the EDM machine and yet not only has it done the vertical shaping (by EDM) but also the scalloping (don't know the correct term, rotary profiling??) as though it's been turned in a lathe. Are there machines that can do the rotary profile as well as the vertical profile? Lastly they show a completed planetary gear assembly that seems to be the drive unit that connects the electric motor of the kart looking thing (electric formula student??) to the wheel and hub, etc. As I say, I'm no expert so would appreciate someone explaining the processes and machines. Thanks in advance.

[@jean-gabrielcanapa1225]

Amazing video :) 1:51 1:55 What are the names of the processes ? Deburring/Vibration polishing ?

[@michaellynch9862]

Vibratory finishing. It removes burrs and sharp corners

[@hadrieneverard8121]

This gear actually has a funnier life than me

[@seeker4430]

Could somebody list the processes that are shown in this video in making the gear? For the benefit of noobs

[@teekello]

2:17 $11 usb microscope from ebay? :D

[@EngineeringAndRestoration]

You'd be surprised how common these things are in manufacturing. Easy to give a quick visual inspection and the quality is good enough just for that.

[@teekello]

Yeah, thats awesome. I use them daily :P

[@adrianvonbrockdorff1091]

or maybe a $2000 Dino-lite ;)

[@vksgears839]

gear chennai

[@NicotinJunky]

Planetary gear in Wheel, nice. But a shame you didn't show the tempering and grinding after.... and the Surfacemassurments not on the Flanks..... well..

[@markliu696]

hey man can I contact you？I want to make a four-motor racing car

[@LiToxHD]

Whats the name of the song ?

[@swikocki]

No checks for gear profile, lead, runout and pitching?

[@zephroth]

All that precision work then they throw it in a vibration grinding set and don't test the dimensions after...

[@MrEpicLion]

Yeah I was a little confused at that part.

[@YszapHun]

i believe the end dimensions were accurate when the vibration grinding was finished. of course they measure it afterwards too, but you also have to measure the part size BEFORE it is vibration grinded because when it is finished, it has to be the perfect size. this is done by testing the abrasives and setting the time and vibrational parameters on the machines. the first few gears made were obviously bad in size, but they adjusted the technology afterwards. this is called indirect measurement!

[@microbuilder]

That wasnt a grider, it was a tumbler, it simply breaks edges, doesnt really change dimensions.

[@ipadize]

depends on how long you let it tumble :)

[@jeffreybell7225]

This vibratory process is likely Accelerated Surface Finishing or (ASF). This method of vibratory finishing uses high density, non-abrasive media with the addition of a chemical accelerant to convert the surface of the part to a state that the asperities can be slowly honed down. This non-directional finish significantly reduces frictional coefficients, thus increasing wear resistance, decreasing crack propagation points and ultimately gaining operational life. Material removal can be negligible at millionths of an inch.

[@JoeyLovesTrains]

Why does the into look like the same formatting to AutoVlog?

[@RelianceMachineryCo]

this is a perfect gear : )

[@akshayg7557]

do they use planetary system?

[@UREindhoven]

Yes, it is an in-wheel compoundend planetary gears set.

[@balthazarnaylor5874]

how about how you made the steel for the gear？

[@UREindhoven]

The steel for the gear was bought.

[@shravan8066]

What is the device that designer is using with the left hand??

[@jimmyvanderhaeghen1111]

It's a HP SpacePilot pro. These 3d mouses are used alot in AutoCad applications to increase productivity.

[@shravan8066]

Thank you for the answer..

[@ruikazane5123]

man, without those we are dead already Thanks

[@RaphaelCh]

It's by watching videos like this one that I realize that Mechanical Engineering was not a bad choice for me.

[@geniferteal4178]

00:54 I think we're missing a lot of this process. It looked like a laser cutting device but then it goes under water or some other liquid and gets effectively machined? They are hiding the proprietary technology I'm just curious how that works I thought it was gonna cut the basic blank but apparently it didn't have to Cut through the metal. it cut 2 specific depths like a milling process. Anyone know the name? I'll look it up whatever this equipment is.

[@geniferteal4178]

EDM is a thermal process for removing unwanted material by applying cycled discharging sparks in the gap between an electrode and a conductive workpiece. This method is typically used for machining refractory metals and hard materials, which are difficult to machine with conventional machining techniques.

[@RexinOridle]

I can probably buy a 2017 BRZ with that money.

[@Uizzj]

A Brz? Might as well buy a civic

[@alexmoore5970]

jerardo rosales I own a brz and it's a phenomenal vehicle, drive one for yourself.

[@Evan2]

alex moore it looks great and it's cheap but it sure as hell isn't quick

[@alexmoore5970]

Buy a WRX, or a used Mustang Gt/ Camaro SS if you want quick, this car is a blast. I have fun revving it to the moon, taking corners like a fool, and just drove JDLs show car, I am excited about turbocharging my own. The show car was limited to 280whp, but trust me when I say that thing was a rocket.

[@binarynumbers7681]

What is the ”cutting”-procedure called? When the gear is formed out of the raw-material?

[@geniferteal4178]

Did you find out? Here I am a year later wondering the same thing.

[@geniferteal4178]

EDM is a thermal process for removing unwanted material by applying cycled discharging sparks in the gap between an electrode and a conductive workpiece. This method is typically used for machining refractory metals and hard materials, which are difficult to machine with conventional machining techniques.

[@hubertbehrendt1438]

It don't seem like a precision gear at all, I mean yeah little bit of surface grinding involved but apart from that EDM machined gear and spline, no gear/bore/O/D grinding involved nothing?

[@thibautjuzeau2922]

0:14 What is the name of this software ??

[@jimmyvanderhaeghen1111]

It's Siemens NX 10 Cad software.

[@msaad42]

which 3d modeling software he is using?

[@thomasramsden4576]

Muhammad Saad Siemens NX 10

[@msaad42]

Thomas Ramsden thanks. I want to learn 3d modeling. I have some experience with pro engineer. Which software would you recommend for production quality 3d models?

[@kzinty]

If licenses are not an issue, NX is the best (used by Apple, Boeing, Redbull, SpaceX) and its still pretty easy to use. If licenses are an issue, than Fusion360 is pretty powerful and free for a year. Fusion also does CAM and FEA.

[@msaad42]

kzinty Thanks for your guidance :)

[@boringsoren]

this almost madee cry

[@tinyboxxx]

This is sick...

[@sing023]

good

[@djdisleksik2119]

Looks like I've ended up on my weird recommendations again

[@brmcf]

that a cool car

[@dnltbrca]

No tempering?

[@UREindhoven]

The gears were tempered, but not all processes could be in the video.

[@stanbondarev9256]

it's disappointing me;/ Carburization and heat treatment is very important stage and maybe the most sophisticated comparing to that was shown.

[@noxiouspro]

what 1:49 process are for

[@gokuljagannath]

Wanna know what grinds my gears? Perfection.

[@AbhishekSharma-gt7im]

That's called quality

[@giordanosilva8336]

can someone explain me what is happening at 1:47 ?

[@samhenninger3727]

Vibratory tumbling, imagine a million little files going over every surface of a part. It's a process for burr removal and smoothing edges :)

[@flashman_tv]

Missing a bit the important part of hardening.

[@UREindhoven]

Unfortunately not all processes could be included in the video.

[@nassimback]

can someone please give me the name of those processes ?

[@simonbarbarasch7169]

Nassim manufacturing

[@nassimback]

Simon Barbarasch yes but specifically pls i mean each step has a name right ?

[@Kamyczek93]

First is design 0:39 grinding 0:55 they probably drill starting hole 0:58 WEDM (Wired Electrical Discharge Machining 1:12 probably griding by hand, some small adjustements 1:20 quality assurence with CMM (coordinate measuring machine) 1:50 Tumble finishing 2:05 probably cleaning (not sure of this) 2:10 roughness measuring with profilometer later on some more measures 2:21 you can see profile line I think that's all. Not sure about all processes naming, english is not my native laguage so I tried searching for words on the internet.

[@nassimback]

Kamyczek93 thank you so much ,i'm very attracted to mechanics these days even know i'm an automatician but i think i can do something usefull with both :)

[@captcha95]

Somewhere inbetween must have been heat treatment as well. Maybe the 2:05 mark has something to do with this. They didn't show the heat treatment, but it sure was done.

[@saifudinbahrudin2891]

What is the title of this song?

[@kieranodonnell864]

Saifudin Bahrudin I second this!

[@wouterandriesse1739]

Saifudin Bahrudin darude sandstorm

[@LR-qi9rj]

never in my life have I seen a machinist wearing a lab coat

[@bucherfrederic623]

what about hardening, maybe one of the most important things..

[@dunichtich100]

Why did the gears not get hardened!?! :0

[@TheKooster31]

1:47 what process is this called? thanks

[@IkarimTheCreature]

vibratory tumbling with ceramic media

[@r7z859]

Before this was a bolt, now a gear, im going places

[@22Tech]

can someone explain what the part with all the small pill looking things is 1:50

[@IkarimTheCreature]

vibratory tumbling, used to polish surfaces and remove burrs.

[@22Tech]

woah i forgot about this comment, thanks for the answer. a lot has happened since then huh @@IkarimTheCreature

[@rajkumarbisoyi7982]

at 0:18 sec what is the device is used.

[@UREindhoven]

It's a 3DConnexion SpacePilot Pro.

[@rajkumarbisoyi7982]

UREindhoven what is the cost?

[@maddoxinc1642]

A motor at each wheel would make ground clearance a lot more practical on a truck.

[@creativelife4453]

really , gear story started with desgin, from hand to with report, many participate to give us one gear

[@ariadiariadi8192]

Surface grinding and wire cut EDM Machine

[@darknesskid94]

What was that device at 0:18 ?

[@IkarimTheCreature]

it's a space mouse, used to orient the camera in cad programs

[@user-eq5hu6yj2n]

Ну і скільки ця деталь коштує??

[@thegooserider7245]

Right, first off I would like to ask yet again! How the hell I got here? Second, I would like to know where to get one of those little F1 cars. They look AMAZING

[@zergdc994]

epic

[@x50music]

1:12 that part really grinds my gears

[@hugh6025]

cease

[@AlphaNerd132]

Was that a plasma torch that operated under water?!

[@IkarimTheCreature]

that was a wire edm machine, it's removing material by creating tiny sparks between a running wire and the work piece.

[@empiirik]

You can imagine how much in such meticulously way producted gear will cost.

[@AnonymousF11]

Have you heard of the gear wars

[@sokcheachea5096]

អស្ចារ្យណាស់

[@marach41]

Gearhead would be proud

[@surazdahal4862]

The attention to the detail given to f1 car parts is insane

[@dorianvincent2101]

It’s not F1 ^^

[@damarwirawan1348]

there will be a time where subatomic distance of precision are possible

[@asaibabd9785]

What is the device name 1:28

[@IkarimTheCreature]

coordinate measuring machine (CMM) used to check dimensions of parts

[@samhenninger3727]

Only wire EDM?? That's incredible if their process is so good it doesn't require hobbing or broaching!

[@ANabih-uo3zy]

When the life of a gear is more epic than your life as a human

[@dha12oks]

You know what really grinds my gea... Sorry couldn't resist...