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Abstract: This paper presents the stress analysis of extended its use [12-14] where he obtained finite-
spur gear teeth for the variation of tooth parameters: difference solutions of a number of mixed boundary
module, pressure angle and teeth number. Gear tooth value problems of simple boundary shapes.
under tip loading as worst condition is considered for In the present paper, the stress and strain analysis of
this analysis. A new formulation of governing spur gear tooth with involute profile is studied by
equations in terms of displacement potential function using the numerical scheme of Finite Difference
ψ has been used in modeling the problem of mixed Method [15-17], taking special care of the boundary
boundary values. This formulation has the capability condition as well as the boundary shapes. Here the
of the conventional formulations in terms of Airy’s stress analysis of the two dimensional involute profile
stress function φ . A computer program developed spur gear teeth under tip loading is done. The effects
due to change in module, pressure angle and number
based on finite difference method is used to solve the
of teeth have been analyzed and presented
spur gear tooth as a plane strain problem with mixed
graphically.
boundary conditions. The numerical results obtained
by this program are discussed to analyze the 2. SPUR GEAR TOOTH AS AN
theoretical facts and compared them with the variation ELASTIC PROBLEM
of gear tooth parameters.
Stress analysis of spur gear teeth was carried out to
Keywords: Spur gear teeth, Mixed boundary observe the effect of different parameters. Gear tooth
condition, Stress analysis under the compressive load near the tip is considered
1. INTRODUCTION for the analysis. Instead of solving the whole gear a
single tooth, as shown in Fig. 1 is selected for this
With the emergence of computer, engineering study. The boundary of the gear tooth inside the gear
analysis is getting more dependent on computers day stock, STUV is considered rigidly fixed with
by day. Computerized process involves in many negligible normal and tangential displacement, i.e.
production system and engineering procedure. In a u n = 0 , ut = 0 . At the location of contact of two gear
product design process the engineering analysis
teeth only the normal component of stress have been
comes after geometric modeling. After a particular
considered. Therefore, the boundary conditions at the
design alternative has been developed in the
geometric modeling process, some form of contact region are σ n = −3.0 × 10 −4 and σ t = 0 . The
engineering analysis often must be performed as part
of the design process. The analysis may take the form y
of stress-strain calculations or dynamic simulation. 0 4 8 12 16 20 24 28 32
The computations are often complex and time
0
consuming, and before the advent of the digital σt= 0,
computer, these analyses were usually greatly σn = -3 x 10-4
4 σn = 0,
simplified or even omitted in the design procedure. σt= 0
Elasticity is now a classical subject and its problems 8
are even more classical. But somehow these stress σn = 0,
σn = 0,
12 σt = 0
analysis problems are still suffering from a lot of σt = 0
shortcomings and thus are being constantly look into
16
[1-8]. The gear tooth is assumed here to be isotropic,
x
⎛ ∂2 ⎞ ⎡ ∂ 2ψ ∂ 2ψ ⎤
( ) ⎢(1 − µ ) 2 + 2 2
∂2 1
⎜ + ⎟σx +σ y =0 (3) vx = − ⎥ (13)
⎜ ∂x 2 ∂y 2 ⎟ 1+ µ ⎢⎣ ∂y ∂x ⎥⎦
⎝ ⎠
E ⎡ ∂ 3ψ ∂ 3ψ ⎤
Replacement of the stress components in Equation σx = ⎢ 2 −µ 3 ⎥ (14)
(1-3) by their relations with the displacement (1 + µ )2 ⎣⎢ ∂x ∂y ∂y ⎥⎦
components u and v makes Equation (3) redundant
⎡ ∂ 3ψ ∂ 3ψ ⎤
⎢ 3 + (2 + µ ) 2 ⎥
E
and transforms Equation (1) and (2) to σy = (15)
(1 + µ ) 2
⎣⎢ ∂y ∂x ∂y ⎦⎥
∂ 2u ⎛1− µ ⎞ ∂ u ⎛1+ µ ⎞ ∂ v
2 2
+ ⎜ ⎟ + ⎜ ⎟ =0 (4) E ⎡ ∂ 3ψ ∂ 3ψ ⎤
∂x 2 ⎝ 2 ⎠ ∂y 2 ⎝ 2 ⎠ ∂x∂y τ xy = ⎢µ − ⎥ (16)
(1 + µ ) 2
⎢⎣ ∂x∂y
2
∂x 3 ⎥⎦
∂ v ⎛1− µ ⎞ ∂ v ⎛1+ µ ⎞ ∂ u
2 2 2
+⎜ ⎟ +⎜ ⎟ =0 (5)
∂y 2 ⎝ 2 ⎠ ∂x 2 ⎝ 2 ⎠ ∂x∂y For the solution of the problem the gear tooth
geometry is divided into a rectangular mesh system.
The problem then reduces to finding u and v in a The governing Equation (7) has been discritized in
two-dimensional field satisfying the two elliptic finite-central difference formula and it is used for the
partial differential equations, (4) and (5). mesh points inside the tooth geometry. The boundary
equations (8-11) are discritized in forward or
backward difference formulae and are used in the rigid boundary. These distributions state that the tooth
boundary points. For the curve boundary, the function deflects like a cantilever with end bending force. In
ψ of the physical boundary point not matching with each section the displacement is more or less uniform.
the rectangular mesh points has been estimated by the The displacements on the left and right boundary
linear interpolation of four neighboring mesh points. within the gear stock are zero on account of the
The detail description of the boundary management rigidity of the boundary as assumed in this analysis.
has already been presented in our earlier papers
[15-17]. A computer program has been developed for 18
solution of the problem. The results are presented 16
Section 5
Section 16
below. 14
Section 23
Section 30
12
4. RESULTS AND DISCUSSIONS
10
4
The distribution of the displacement component, u
4
u X 10
2
along x -axis, with respect to horizontal grid position, 0
y / k , for different sections of gear tooth as shown in -2
5
is positive everywhere in the right half portion of the -8
16
tooth and negative in the remaining half portion as the -10
23
displacement here in the x -direction is positive. -12
30
-14
The tooth loading as shown in Fig. 1 may be -16
x
considered as equivalent to an axial compression and 0 4 8 12 16 20 24 28 32
28
stock and finally vanishes to zero at far below the root 24
section. The displacements at both ends of the section 20
within the gear stock are also zero. This is due to the 16
fact that, at these points, they are specified rigidly 12
fixed. 8
0
y / k presented in Fig. 3, shows that the displacement
0 2 4 6 8 10 12 14 16
is always positive. The displacement v is maximum
Distance, y / k
at the upper sections and gradually decreases towards
the bottom and vanishes completely at the bottom Figure 3. Distribution of v along
section which is inside the gear stock, specified as Different Sections of Profile B
compression at the right side is higher than that of The distribution of stress component τ xy at different
maximum tension at the left side. This conforms to
sections of the tooth with respect to grid distance
the loading on the tooth. The load is applied normally
y / k is shown in Fig. 6. The distributions of this
on the left surface of the involute tooth near the tip. It
has two components, the major one parallel to y that shear stress over the different cross-sections are
completely different from those observed in long
causes bending which produces compression at the
beams but in complete harmony with that found in
right side and tension at the left side, the other minor
deep beams by Ahmed [14]. The distribution at
component parallel to x that causes pure compression
sections close to the contact point resembles that
of the entire section. That is why in the left side of the
usually assumed for the case of direct shear. But, as
tooth the net tension is reduced and in the right side
the distance of the sections from the contact section
the net compression is increased. Therefore, the worst
increases, the distribution becomes similar to that
condition is at the right root region of the tooth in this
found by Filon, as reported in [18]. The distribution of
particular case. The stress magnitude just below the
shear stress on sections near the root is found to be
root section is less and gradually decreases to the
similar to that obtained by Ahmed et al. [13] at the
center of the gear but non zero on the bottom
fixed end-section of deep beams. As the root section
boundary which is specified as rigidly fixed. Root
of the gear tooth is similar to fixed end of beam, the
section is at the end of dedendum but, due to fillet
distribution of shear stress as obtained here on the
radius, the maximum stress develops just above this
section near the root is quite justified. The magnitude
section. The section immediately above the root
of shear stress becomes maximum at section before
section is subjected to the maximum stress at the
root, because of the effect of stress concentration due
compression side. In each section at centerline of gear
to high curvature change in the fillet. Beneath the
profile, the stress is negative. Therefore the
root-section, on the sections within the circular stock
compression zone is larger than the tension zone. This
is due to the same reason for which the compression is 3
Section
y
5
higher. Moreover, the stress distribution on section
near load is completely different from that on other 2 16
1 30
is much higher, which decreases at a very fast rate as
the distance from it increases. This phenomenon
σy X 104
x
0
conforms to the Saint Venants' principle.
6 y
S ec tio n -1
5
16
4 Section 5
23 -2
Section 16
30 Section 23
2 Section 30
x
-3
0 4 8 12 16 20 24 28 32
σ X 104
0 Distance, y / k
x
D ista n ce , y / k
2 16
Section 5
Section 16 23
near the root of the tooth and its value changes from
maximum tension at the left to the maximum -3
Height, x/h
15 0 -6e-5 -1e-4
-4e-5
Height, x/h
0 -2e-5 -1e-4
-1e-4
0 -2e-4 8e-5
0
-2e-4
-2e-4 1e-4 1e-4
-3e-4
-2e-4 20 1e-4 1e-4
3e-4
2e-4
0-1e-4 -2e-4
-2e-4-3e-4 2e-4
2e-4
20 -8e-5 -5e-4
-4e-4
-4e-4
-3e-4
-3e-4 6e-5
8e-5
1e-4 2e-5 1e-4
-6e-5
-4e-5
-2e-5 2e-5
4e-5
2e-41e-4 6e-5
1e-4
2e-4
0-2e-5 2e-4
0 2e-4 2e-5 2e-4 2e-5
2e-4 0
0 0 -8e-5 -3e-4-8e-50 2e-4 6e-5
4e-5
4e-5 -4e-4
-4e-4 -2e-5
-4e-5
-6e-5
-1e-4
-1e-4 6e-5 2e-4
3e-4
2e-4
3e-4 8e-5
1e-4 3e-4
3e-4
-8e-5 -3e-4
-3e-4 2e-4
2e-4 3e-4
2e-4
2e-4
2e-4 6e-5
-6e-5
-2e-5 -1e-4
-4e-5 -1e-4
-1e-4 -4e-4 25 6e-5 1e-4
25 -8e-5
-4e-5
-6e-5 -4e-4
-3e-4-2e-4
-3e-4
-3e-4
-3e-4 6e-5 1e-41e-4
-2e-5 2e-5 -2e-4
-2e-4
-2e-4 8e-5
-1e-4
-2e-4
-1e-4 4e-5
-1e-4
0 0 4e-5
30
30
-8e-5
0 -6e-5 2e-5 2e-5
34 34
0 5 10 15 20 25 30 0 5 10 15 20 25 30
0
and decreases with the increase of the module value,
while the other parameters were unchanged. This is
-2
due to the fact that with increase of module, pitch
diameter of the gear tooth increases causing the tooth
-4 to become bulkier and stronger. Again, with the
ProfileB (m10, fi20, N25) increase of module, the fillet radius of the tooth
ProfileA (m10, fi25, N25)
-6 increases which would cause to have lesser impact in
0 4 8 12 16 20 24 28 32 the root region (critical region) of the gear tooth. The
Distance, y / k
increase of module means the increase of the tooth
Figure 10. Comparison on pressure angle variation width from top to bottom. As a result, the stress is
observed to be less in the wider tooth for the same
of σ x at root section of gear tooth Profile A and B loading.
condition. Although it can be generally concluded, An inverse characteristic can be found from Fig. 15,
that with the decrease in the pressure angle the shear for the effect of module variation on τ xy . Although,
stress decreases, but keeping in mind that the effects when only the magnitude is considered, it is observed
of pitch diameter in not taken into account. Moreover, that the profile with lower module number have the
the shear stress was found to be always negative for
2
each case. ProfileC (m10, fi14.5, N41)
ProfileD (m10, fi20, N41)
4
2
τxy x 104
0
σx x 104
-1
-2
-2
ProfileC (m10, fi14.5, N41) 0 4 8 12 16 20 24 28 32
ProfileD (m10, fi20, N41) Distance, y / k
-4
0 4 8 12 16 20 24 28 32
Distance, y / k Figure 13. Comparison on pressure angle
Figure11. Comparison on pressure angle variation variation of τ xy at root section of gear tooth
of σ x at root section of gear tooth Profile C and D Profile C and D
4
ProfileB (m10, fi20, N25)
ProfileA (m10, fi25, N25)
2
2
σx x 104
0
τxy x 104
-2
0 σx Stress along x
-2
σy Stress along y
τ xy Shear stress
-4 ProfileF (m10, fi20, N32) σx Dimensionless stress along x , σ x / E
ProfileD (m10, fi20, N41)
ProfileE (m10, fi20, N23)
σy Dimensionless stress along y , σ y / E
-6
0 4 8 12 16 20 24 28 32 σn Normal stress
Distance, y/k
σt Tangential stress
Figure 16. Comparison on No. of teeth
σn Dimensionless normal stress, σ n / E
variation of σ x at root section of gear tooth
σt Dimensionless tangential stress, σ t / E
Profile D, E and F
σ1 , σ 2 Principal stresses
τ max Maximum shear stress
5. CONCLUSION l, m Direction cosines
This paper discusses the general effect of tip load as
observed in different gear teeth profiles. The paper
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