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Research Article
Accepted 25 December 2013, Available online 30 December 2013, Vol.3, No.5 (December 2013)
Abstract
The contact stress in the mating gears is the key parameter in gear design. 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 theoretical Hertzian equation values. For the analysis, steel and grey cast iron are
used as the materials of spur gear. The spur gears are sketched, modeled and assembled in ANSYS DesignModeler. As
Finite Element Method (FEM) is the easy and accurate technique for stress analysis, FEA is done in finite element
software ANSYS 14.5. Also deformation for steel and grey cast iron is obtained as efficiency of the gear depends on its
deformation. The results show that the difference between maximum contact stresses obtained from Hertz equation and
Finite Element Analysis is very less and it is acceptable. The deformation patterns of steel and grey cast iron gears depict
that the difference in their deformation is negligible.
Keywords: ANSYS, Contact Stress, Finite Element Analysis, Spur Gear.
1. Introduction
1
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Vivek Karaveer et al
International Journal of Current Engineering and Technology, Vol3., No.5 (December 2013)
(1)
Unit
Kg/m3
K-1
MPa
MPa
MPa
Steel
7850
1.2e-5
0.3
2e5
250
460
Unit
Symbol
Number of Teeth
Pitch Circle
Diameter
Pressure Angle
Addendum Radius
Dedendum Radius
Face Width
Shaft Radius
Value (For
both gears in
assembly)
20
Mm
127
0
Mm
Mm
Mm
Mm
RA
RD
B
Rs
20
69.85
55.88
25.4
31.75
(2)
Here
is the factor of safety which can be taken from
the ANSYS results or other
tables. Equation (2) gives
the allowable maximum contact stress in the mating gears.
In this paper, factor of safety is taken from ANSYS
results. But minimum factor of safety from the ANSYS
results is preferred in order to get accurate allowable
maximum contact stress at the point of contact of gear
teeth (Mr. Bharat Gupta et al 2012).
Now, Torque is given by,
1694.7725e3 (N-mm) =
* 31.75 (mm)
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Vivek Karaveer et al
International Journal of Current Engineering and Technology, Vol3., No.5 (December 2013)
grey cast iron gears. Also the deformation is found out for
both the gears.
= 53378.6614 N
Case I- Steel Spur Gear:
4.1 Meshing
For steel gear, equation (1) becomes,
= 2601.7984 MPa
From Fig. 6, factor of safety for steel gear is 1.1538.
From (2),
=
= 2254.9821 MPa
Case II- Grey Cast Iron Spur Gear:
For grey cast iron gear, equation (1) becomes,
= 2334.6414 MPa
From Fig. 9, factor of safety for grey cast gear is 1.
From (2),
=
= 2334.6414 MPa
4. Finite Element Analysis
Fig. 3 Meshing
Finite Element Method is the easy technique as compared
to the theoretical methods to find out the stress developed
in a pair of gears. Therefore FEM is widely used for the
stress analysis of mating gears. In this paper, finite
element analysis is carried out in ANSYS Workbench 14.5
to determine the maximum contact stresses for steel and
Vivek Karaveer et al
International Journal of Current Engineering and Technology, Vol3., No.5 (December 2013)
(Hertz)
(MPa)
2254.9821
2334.6414
(ANSYS)
(MPa)
2261.2052
2365.1782
Difference
(%)
0.28
1.29
Conclusions
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