A project seminar on

FINITE ELEMENT ANALYSIS OF A GEAR TOOTH

USING ANSYS AND STRESS REDUCTION BY
STRESS RELIEF HOLE
By

P.BRAHMESHWAR RAO (08145A0310)

G.SURYA MOHAN REDDY (07141A0309)
M.HEMANTH (07141A0305)
K.V.ANURAG REDDY (07141A0310)

Under the guidance of

Mr. Y.NAVEEN
(Asst.Proffessor)
ABSTRACT

 The main aim of this project is to model a spur gear by

PRO-E. The model is then imported to ANSYS.

 To reduce the stress in a gear tooth, with the help of a

stress relief hole, to the minimum value, without affecting the
quality.
PROJECT OVERVIEW
 A plane area element (plane stress with thickness) was chosen
and the model for the gear tooth whose stress was to be
studied, was created and the Von Misses stress was calculated.

 Then various case studies were conducted using a stress relief

hole at different positions and the Von Misses stress value in
each case was compared with the Von Misses stress value
without hole.

 After a number of case studies, we were able to optimize the

position of the hole, because of which, stress in the gear tooth
was the minimum.
INTRODUCTION ABOUT GEARS
 Gears are used to transmit motion from one shaft to another
or between a shaft and slide, this can be accomplished by
successively engaging teeth.
 Gears use no intermediate link or connector & transmit the
motion by direct contact.
 The two bodies have either a rolling or a sliding motion
along the tangent at point of contact and no motion is possible
along the common normal.
   Gear design has evolved to such a level that throughout the
motion of each contacting pair of teeth the velocity ratio of the
gears is maintained fixed and the velocity ratio is still fixed as
each subsequent pair of teeth come into contact. 
GEAR TERMINOLOGY:-
 Addendum circle
 Dedendum circle
 Addendum
 Dedendum
 Clearance
 Face of tooth
 Flank of tooth
 Circular pitch
 Pitch point
 Base circle
CLASSIFICATION OF GEARS
 Gears are classified according to the relative position of their shaft axes as
follows.
1) Parallel shaft
Spur gears
Helical gears
Herringbone gear
2. Intersecting shaft
Straight bevel gears
Spiral gears
Zerol bevel gears
3) Skew shaft
Crossed helical gears
Worm gears
SPUR GEAR
 Spur gears have straight teeth parallel to the axis and thus, are not subjected
to axial thrust due to tooth load.

 At the time of engagement of the two gears, the contact extends across the
entire width on a line parallel to the axis of rotation.

 This results in sudden application of load, high impact stress and excessive
noise at high speeds.
HELICAL GEAR
 In helical gear, the teeth are curved,
each being helical in shape.

 At the beginning of engagement, contact occurs only at the point of leading

edge of the curved teeth. As the gear rotates, the contact extends along the
diagonal line across the teeth.

 Thus the load application is gradual which results in low impact stresses
and reduction in noise . Therefore helical gears can be used at high
velocities than spur gears and have greater load carrying capacity
BEVEL GEARS

 STRAIGHT BEVEL GEARS : The teeth are straight , radial to the point of
intersection of the shaft axes and vary in cross section through out their
length.

 SPIRAL BEVEL GEAR: When the teeth of the bevel are inclined at an
angle to the face of the bevel , they are known as Spiral or helical bevels.

 ZEROL BEVEL GEARS: Spiral bevel gears with curved teeth but with a
zero degree spiral angle are known as Zerol bevel gears
WORM GEAR
 Worm gear is a special case of a spiral gear

 In which the larger wheel, usually, has a hallow or concave shape such that
a portion of the pitch diameter of the other gear is enveloped on it.

 The smaller of the two wheel is called the worm which also has a large
spiral angle
ADVANTAGES:

 Provide Positive Drive without slip.

 Suitable for high speed , high torque & high power transmission.
 Properly designed & properly maintained gear system can run over decades.
 Very high transmission ratio is practicable.
 Compact machine train in limited space.

DISADVANTAGES:

 Needs Proper Lubrication System. which involve high cost.

 Needs Proper alignment- misaligned gear train will damage within very short time.
 Misaligned gear mesh or lack of lubrication will make noise & vibration.
 Spare gear is costly and proper replacement gear is difficult to procure in many
cases it is available only from OEM source.
 Require skilled technician to maintain.
TYPES OF FAILURES IN GEARS

Moderate wear Pitting

Rippling Ridging
Materials Notes Applications

Ferrous

Cast Iron Low cost easy to machine with Large moderate power, commercial
high damping gears

Cast Steels Low cost reasonable strength Power gears with medium rating to
commercial quality

Plain carbon steels Good machining can be heat Power gears with medium rating to
treated commercial/medium quality

Alloy Steels Heat Treatable to provide highest Highest power requirement. For
strength and durability precision and high precision

Stainless Steels (Aust) Good corrosion resistance. Non Corrosion resistance with low
magnetic. power ratings. Up to precision
quality

Stainless Steels (Mart) Hardenable , reasonable, corrosion Low to medium power ratings Up
resistance , magnetic to high precision levels of quality
 Non-ferrous metals
Aluminium alloys Light weight ,non corrosive and Light duty instrument gears up to
good mach inability high precision quality

Brass alloys Low cost, non-corrosive, excellent
machinability
Bronze alloys Excellent machinability low friction
and good compatibility with steel
Magnesium alloys Light weight with poor corrosion
resistance.
Nickel alloys Low coefficient of thermal
expansion. poor machinability
Titanium alloys High strength, for low weight, good
corrosion resistance
Di-cast alloys Low cost with low precision and
strength
Sintered powder alloys Low cost low quality, moderate
strength
low cost commercial quality gears.
Quality up to medium precision
For use with steel power gears.
Quality up to high precision
Light weight low load gears. Quality
up to medium precision
Special gears for thermal
applications to commercial quality
Special light weight high strength
gears to medium precision
High production, low quality gears
to commercial quality
High production, low quality to
moderate commercial quality
Gear has been developed by using PRO-E
COMMANDS USED
 Curve id(by using program)

 Sketch 1

 Extrude 1

 Extrude cut 2

 Pattern of Extrude 2

 Round 1

 Round 2
PROGRAM TO GENERATE CURVE ID
 /* For cylindrical coordinate system, enter parametric equation
 /* in terms of ‘t’ (which will vary from 0 to 1) for ‘r’, theta and ‘z’
 /* For example: for a circle in x-y plane, centered at origin
 /* and radius = 4, the parametric equations will be:
 /* r=4
 /* theta = t * 360
 /* z=0
 /*-------------------------------------------------------------------
 N o t=17
 P angle=20
 M =8
 x=.15
 O d=128
 R d=92
 P cd=not*m

 B cd=p cd*cos(p angle)

 R base=b cd/2

 T t=(((3.141592654)*m)/2)+(2*m*x*tan ( pangle ))

 K =b cd*((tt/ pcd)+((tan(pangle)-((pangle*(3.141592654)))/180)))

 Gamma =(((bcd*(3.141592654))-(not*k))/(not*2))*(360/(bcd*(3.141592654)))

 R =r base/(cos(t*40))

 Inv =tan(t*40)-(((t*40)*(3.141592654))/180)

 Theta =(((inv*180)/3.141592654)+gamma)

 Z =0
Spline is generated by using program
STRESS CONCENTRATION

 The fracture of a material is dependent upon the forces that

exist between the atoms.

 Because of the forces that exist between the atoms, there is a

theoretical strength that is typically estimated to be one-tenth
of the elastic modulus of the material.

 The stress is concentrated around the crack tip or flaw

developing the concept of stress concentration.
METHODS TO REDUCE STRESS
CONCENTRATION
A number of methods are available to reduce stress
concentration in machine parts. Some of them are as follows:
 1. Provide a fillet radius so that the cross-section may change
gradually.

 2. Sometimes an elliptical fillet is also used.

 3. If a notch is unavoidable it is better to provide a number of

small notches rather than a long one. This reduces the stress
concentration to a large extent.

 4. If a projection is unavoidable from design considerations it

is preferable to provide a narrow notch than a wide notch.
SURFACE WHICH IS TO BE ANALYSED
1
VOLUMES
TYPE NUM
MAR 16 2011
13:20:36

Y
X
Z
1
NODAL SOLUTION
STEP=1
SUB =1 MAR 16 2011
TIME=1 13:18:11
SEQV (AVG)
DMX =.075412
SMN =.211E-04 MN
SMX =136.713

Y
MX X
Z

.211E-04 30.381 60.761 91.142 121.523

15.19 45.571 75.952 106.332 136.713

Without hole von misses stress = 136.716N/mm2

1 NODAL SOLUTION
STEP=1
SUB =1
TIME=1
MN
SEQV (AVG)
PowerGraphics
EFACET=1
AVRES=Mat
DMX =.075724
SMN =.204E-04
SMX =133.361

XV =1
Y YV =2
MX X ZV =3
Z DIST=100.909
XF =-.366964
YF =.183072
ZF =-.001143
Z-BUFFER
.204E-04
14.818
29.636
44.454
59.271
74.089
88.907
103.725
118.543
133.361

Position of the hole :x=30,y=60,dia=3

Von misses stress value=133.36 N/mm2
 1 NODAL SOLUTION
STEP=1
SUB =1
TIME=1
SEQV (AVG)
PowerGraphics
EFACET=1
MN
AVRES=Mat
DMX =.075491
SMN =.170E-04
SMX =136.212

XV =1
Y YV =2
MX
X ZV =3
Z DIST=100.909
XF =-.365144
YF =.185921
ZF =-.001269
Z-BUFFER
.170E-04
15.135
30.269
45.404
60.539
75.673
90.808
105.943
121.077
136.212

Position of the hole : x=30,y63,dia=1mm

Von misses stress value = 136.212N/mm2
1 NODAL SOLUTION
STEP=1
SUB =1
TIME=1
SEQV (AVG)
PowerGraphics
MN EFACET=1
AVRES=Mat
DMX =.075717
SMN =.289E-04
SMX =135.663

XV =1
Y YV =2
MX X ZV =3
Z DIST=100.91
XF =-.367417
YF =.182698
ZF =-.001001
Z-BUFFER
.289E-04
15.074
30.147
45.221
60.295
75.368
90.442
105.516
120.589
135.663

Position of the hole :x=28,y=58,dia=3

Von misses stress value = 135.663N/mm2
1 NODAL SOLUTION
STEP=1
SUB =1
TIME=1
SEQV (AVG)
PowerGraphics
MN EFACET=1
AVRES=Mat
DMX =.075632
SMN =.221E-04
SMX =135.639

XV =1
Y YV =2
MX
X ZV =3
Z DIST=100.909
XF =-.367262
YF =.18355
ZF =.357E-03
Z-BUFFER
.221E-04
15.071
30.142
45.213
60.284
75.355
90.426
105.497
120.568
135.639

Position of the hole :x=35, y=60,dia=2mm

Von misses stress = 135.639N/mm2
CONCLUSION:-
By creating hole in the gear, we can alter stress in the gear. Stress reduction
is neither directly nor inversely proportional to the Stress Relief Hole Diameter. Stress
Reduction is neither directly nor inversely proportional to the position of the stress
relief hole. Horizontal shift of the hole position has larger effect on the stress value then
the vertical shift. Better results on stress reduction, were observed on the negative side
of the load point, for each tooth By optimizing the diameter and position of the stress
relief hole, we can reduce the stress value in a gear tooth by a considerable amount,
without affecting the functioning of the gear (In this problem, we could reduce stress
from 136.731N/mmA2 to 133.36 N/mmA2 at x=30,y=20 with hole dia 3)
QUERIES ?
THANK YOU