DESIGN AND STRUCTURAL ANALYSIS

OF SPUR GEAR USING VARIOUS

MATERIALS

PROJECT GUIDED BY SUBMITTED BY

SUBASH. S MUHAMMED ALTHAF-1115217072
MUHAMMED NAFI-1115217071
JESWIN V-1115217056
RENJU R-1115217088
SAMBHU GOPAL-1115217092
ABSTRACT
Gears are commonly used for transmitting power. They develop high stress
concentration at the root and the point of contact. This paper presents the
stress analysis of mating teeth of spur gear to find maximum contact stress in
the gear teeth.
The results obtained from Finite Element Analysis (FEA) are compared with
original gear material values. For the analysis, Carbon Steel , Aluminum 6351

Alloy,Aluminum Alloy AMC225xE, Boron Carbide are used as the materials of spur
gear.The spur gears are sketched, modeled and assembled in AUTOCAD, creo
2.0 and Ansys workbench.
As Finite Element Method (FEM) is the easy and accurate technique for stress
analysis, FEA is done in finite element software ANSYS 13. Also deformation
for Carbon Steel, Aluminum 6351 Alloy, Aluminum Alloy AMC225xE, Boron Carbide is
obtained as efficiency of the gear depends on its deformation.
 INTRODUCTION
Gears are used for a wide range of industrial applications. They have varied application
starting from textile looms to aviation industries. They are the most common means of
transmitting power. They change the rate of rotation of machinery shaft and also the axis of
rotation. For high speed machinery, such as an automobile transmission, they are the optimal
medium for low energy loss and high accuracy. Their function is to convert input provided by
prime mover into an output with lower speed and corresponding higher torque. Toothed gears are
used to transmit the power with high velocity ratio. During this phase, they encounter high stress
at the point of contact.
A pair of teeth in action is generally subjected to two types of cyclic stresses:
i) Bending stresses inducing bending fatigue ii) Contact stress causing contact fatigue.
Both these types of stresses may not attain their maximum values at the same point of
contact. However, combined action of both of them is the reason of failure of gear tooth leading
to fracture at the root of a tooth under bending fatigue and surface failure, due to contact fatigue.
When loads are applied to the bodies, their surfaces deform elastically near the point of
contact. Stresses developed by Normal force in a photo-elastic model of gear tooth are shown in
the Fig.1.1. The highest stresses exist at regions where the lines are bunched closest together.
The highest stress occurs at two locations:
•At contact point where the force F acts
•At the fillet region near the base of the tooth.

Photo-elastic Model of gear tooth

The surface failures occurring mainly due to contact fatigue are pitting and scoring. It is a
phenomenon in which small particles are removed from the surface of the tooth due to the high
contact stresses that are present between mating teeth. Pitting is actually the fatigue failure of
the tooth surface. Hardness is the primary property of the gear tooth that provides resistance to
pitting. In other words, pitting is a surface fatigue failure due to many repetitions of high contact
stress, which occurs on gear tooth surfaces when a pair of teeth is transmitting power. Gear
teeth failure due to contact fatigue is a common phenomenon observed. Even a slight reduction
in the stress at root results in great increase in the fatigue life of a gear.
 For many years, gear design has been improved by using improved material,
hardening surfaces with heat treatment and carburization, and shot peening to improve
surface finish etc. Few more efforts have been made to improve the durability and
strength by altering the pressure angle, using the asymmetric teeth, altering the
geometry of root fillet curve and so on. Some research work is also done using the stress
redistribution techniques by introducing the stress relieving features in the stressed zone
to the advantage of reduction of root fillet stress in spur gear. This also ensures
interchangeability of existing gear systems. The studies in which combination of circular
and elliptical stress relieving features are used obtained better results than using circular
stress relieving features alone which are used by earlier researchers. In this research
work, an aero-fin shaped stress relieving feature is tried. A finite element model with a
segment of three teeth is considered for analysis and a stress relieving feature of various
sizes are introduced on gear teeth at various locations.
LITERATURE REVIEW

PINAKNATH PEWANJI., This paper analyses the bending stresses characteristics of an involute
spur gear tooth under static load conditions.The tooth profile is generated using catia and analysis
is carried out by ansys software. The stress at the tooth root are evaluated analytically using
existing theoretical models. ANUJ NATHAN . This paper modeled the spur gear using pro-e
software. The impact analysis for cast steel and composite materials are studied. Finally
comparing and analyzing the composite gears with existing cast steel gear is to be done using
ANSYS 13.0. S.MAGENDRAN, K.M.EAZHIL .This paper modeled the spur gear using solid
works software. The weight reduction and stress distribution for cast steel and composite
materials are studied. Finally compare and analyzing the spur gear using ansys software.
DEVENDRA Singh. In this paper modeled the spur gear and study about gear drive design and
analysis is carried out with the help of pro-e and ansys and improve the static and dynamic
characteristics of gear drive.
LITERATURE REVIEW

PINAKNATH PEWANJI., This paper analyses the bending stresses characteristics of an involute
spur gear tooth under static load conditions.The tooth profile is generated using catia and analysis
is carried out by ansys software. The stress at the tooth root are evaluated analytically using
existing theoretical models. ANUJ NATHAN . This paper modeled the spur gear using pro-e
software. The impact analysis for cast steel and composite materials are studied. Finally
comparing and analyzing the composite gears with existing cast steel gear is to be done using
ANSYS 13.0. S.MAGENDRAN, K.M.EAZHIL .This paper modeled the spur gear using solid
works software. The weight reduction and stress distribution for cast steel and composite
materials are studied. Finally compare and analyzing the spur gear using ansys software.
DEVENDRA Singh. In this paper modeled the spur gear and study about gear drive design and
analysis is carried out with the help of pro-e and ansys and improve the static and dynamic
characteristics of gear drive.
Design of Gear Tooth
The involute spur gear used for the current analysis has the following specifications
1. 16 Tooth
2. Diametrical Pitch of 8.3
3. Pressure Angle of 20o
Gear Geometry
Here we present the calculations for the gear we will use for our stress
concentration reduction studies.As given in
Shigley[8], the gear geometry calculations are as follows:
Considering the pressure angle(φ)= 200
Pitch circle Dia. (PCD) = module(m) x no. of teeth
Tooth thickness = (π x module) /2
Root fillet = 0.2 x module
Addendum Dia.(Da)= PCD +2 x module
Dedendum Dia.(Dd) = PCD – 2.5 x m
Base circle dia. (Db) = PCD x cos φ
Parameters of gear:
Module (m) =2
Pitch circle dia (d) = 48mm
No. of teeth (N) = 16
Tooth thickness (t) = 4.74mm
Root fillet = 0.6mm
Addendum dia(Da)] =54mm
Dedendumdia (Dd) = 40.5mm
Base circle dia (Db) = 45.105mm
Material used: Steel
Properties of Steel: Young‟s modulus = 21000 MPa
Poison‟s ratio = 0.3
Gear Design Calculations:
The Pitch Diameter (D) = 48mm
The Pitch Radius (R) = D/2 =24
The Base Circle Diameter (DB) = D * COS (PA) = 48 * COS (20 deg) = 45.105
The Base Circle Radius (RB) = DB/2 = 22.5525
The Addendum (a) = 1/P = 1/8.31 = 0.1203
Dedendum (d) = 1.157/P = 1.157/8.31= 0.1392
Outside Diameter (DO) =N+2/N/D= 54.0054
Outside Radius (RO) = 27.0027
Root Diameter (DR) = D-2*d = 47.7216
Root Radius (RR) =23.8608
For method [9] described below following calculations are also required:
1. Circumference of the Base circle, (CB) = Pi * (DB) = Pi * 45.105= 141.7015
2. 1/25th of the Base Circle Radius, (FCB) =2.81
3. Number of times that FCB can be divided into CB, (NCB) = 50.42
4. 360 degrees divided by NCB, (ACB) = 7.14
5. Gear Tooth Spacing (GT) = 360/T = 22.5degrees
2D Design
Using software: AUTO CAD
3D MODELING
USING SOFTWARE: CREO 2.0
ANALYSIS
USING SOFTWARE: ANSYS WORK BENCH
REFERENCES
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Thank you