Contact stress and fatigue stress analysis of spur

and helical gear

Contact stress analysis:
Contact Stress analysis for gear teeth is regarded as
a limiting factor for designers. Stress analysis focuses on the
determination of the regions of stress concentration where
failure or fracture may be initiated. At this point, the change in
the load is one of the elements that is involved in surface pitting.
A preexisting pit aggravates the operating condition with noise
and vibration, and if this pit is left as it is, an adventitious crack
can be induced.
There are two methods used for analyzing the
meshing gear teeth. The first is to apply the concentrated load at
the load position directly. Then, the bending stress of the gear
can be calculated. This method is being widely used owing to its
simplicity, but the contact stress cannot be calculated. The
second method is used for the meshing gears by applying a
torque on the gear or pinion after modeling both the gear and the
pinion. Here 3-D modeling carried out by PRO-E.

Fatigue stress analysis:

Fatigue stress deals with the possible interactions
between contact fatigue and dynamic tooth loads on gears. A
specific 3D dynamic gear model is combined to contact fatigue
models accounting for crack initiation and propagation.
Most materials will fracture when submitted to
periodic loads over a large number of cycles. In the case of
gears, two prominent modes of fatigue damage have been
identified: (i) tooth root bending fatigue and (ii) contact fatigue
(often associated with surface pitting) which are accounted for
in international standards such as AGMA.The complete process

of fatigue failure of mechanical elements may be divided into

(a) micro-crack nucleation; (b) short crack growth; (c) long
crack growth and (d) occurrence of final failure. The first two
stages are usually termed as crack initiation period while long
crack growth is refer to as crack propagation period. The
complete service life of mechanical elements N can then be
determined from the number of stress cycles Ni required for
fatigue crack initiation and the number of stress cycles NP
required for a crack to propagate from the initial to the critical
crack length and failure as N=Ni+NP.

Design specifications of spur gear:

The spur gear is modeled on the basis of the data
are as follows, I=1.5 , module=4 , power= 20kw , z1=14(pinion)
, z2=21(wheel).
The material we used for spur gear is C45.The
chemical composition of C45 is
Carbon = 0.42-0.50%
Silicon = <0.40%
Mn
= 0.50-0.80%
S
= < 0.045%
Ni
= <0.045%
Cr
=0.40%
Mo
=<0.10%
Cr+mo+ni=<=0.63

Design calculation of spur gear:

The design calculations and the values are given
below,

For pinion z1(14 teeth),

Pitch diameter=mz1=56
Root diameter=pitch diameter-2.5m=46
Tip diameter=(z1+2)m=64
Base diameter=pitch diameter*cos20=52.62
Radius(r)=base diameter/2=26.31
Circular pitch=3.14/pitch diameter=0.05607
Diametrical pitch=3.1416/circular pitch=56.02

For wheel Z2(21 teeth),

Pitch diameter=mz2=84
Root diameter=pitch diameter-2.5m=74
Tip diameter=(z2+2)m=92
Base diameter=pitch diameter*cos20=76.93
Radius(r)=base diameter/2=39.465
Circular pitch=3.14/pitch diameter=0.0373
Diametrical pitch=3.1416/circular pitch=84.22
According to this value the spur gear is modeled by
using PRO-E. The involute curve of the both pinion and wheel
are created by using the equation,
r = (radius)
ang = t * 90
s = (PI * r * t ) / 2
xc = r * cos(ang)
yc = r * sin(ang)
x = xc + ( s * sin(ang))
y = yc - ( s * cos(ang))
z=0

Current status of the project:

The spur gear was modeled and
assembled by the above values and PRO-E. The
meshing of gears are in successful. The ongoing

process is the analysis of mating gears by ANSYS

12.0.