The 3th Post Graduate Conference of Mechanical Engineering

(Mech-PGCON-2017)

Stress Analysis of Asymmetric Spur

Gear by using Finite Element Method

• Presented by: Mr. Anup S. Banate

• Guided By: Prof. S. R. Patil
• College Name: AISSMS COE, Pune
• College Code: 021

1
Content

1. Introduction
2. Problem statement
3. Aim and objectives
4. Literature review
5. Methodology
6. Modeling of Involute Spur Gear
7. Finite Element Analysis
8. Result and discussion
References
2
 Introduction
• Gears are mechanical element used for power
transmission, change of speed and magnitude like in
gearbox
• Pitting generally appears on operating surface of gear
teeth
• Operating surface is small area of contact points
• Pitting due to high contact stress
• Computer simulation tools to get more accurate
solution to the theoretical model

3
 Problem Statement
• Contact stress causes severe pitting actions on the
surface of teeth in contact as well as in the
unidirectional loading of gear application, high
stresses and deformation developed on drive face as
compared to the rare face. This leads to catastrophic
failure gear system. Therefore, to satisfy such
requirement a new safe design of spur gear to serve
the required application which will minimizes the
stresses in the gear

4
 Aims and Objectives
• To study the effect of asymmetric gear profile over
symmetric gear profile
• To minimized the contact stresses in spur gear
• To select the type of asymmetricity and root radius
for the gear

5
 Literature Review
• In 1998 Alexander Kapelevinch who present a method of research and design
of gears with asymmetric teeth that enable to increase load carrying capacity,
reduced weight, size and vibration.

Figure : Involute asymmetric teeth

6
 Literature Review
• Seok-Chul Hwang, studied a contact stress analysis for pair
of gears in mesh during rotation by using FEA and AGMA.
contact stress in a pair of mating gears is stricter than that of
the AGMA at LPSTC. Explained method of analysis of
gear for stress.
• Ali Raad Hassan presented work on the contact stress
analysis of teeth of the mating spur gear by creating
program to plot position of gear for 3°. Stress are high at
engagement , disengagement and during single tooth
contact.

7
 Literature Review
• Santosh Patil evaluated contact pressure of a gear pair along
the line of action using finite element analysis.

Figure : Comparison plot of contact pressure/stress along the line of action

• Santosh Patil presented a work on the effect of coefficient
of friction along the line of action of a spur gear using
lagranges multiplier in Finite Element Method. Increase in
coefficient of friction from 0 to 0.3 result in 10 % increase
in stress.
8
 Literature Review
• Rameshkumar, G. Venkatesan and P. Sivakumar studies the
Finite Element Analysis of High Contact Ratio (HCR) and
Normal Contact Ratio (NCR) Gear. HCR results in 19% less
contact stress than NCR gear.
• Praveen Silori et al mainly focuses on the study of effect
variation of root radius on stress and fatigue life of AISI
4140 steel and Ti6242S material spur gear assembly.
• Santosh Patil et al presented work on effect of helix angle
and coefficient of friction on the contact stresses among the
helical gear pairs, under static conditions, by using a 3D
finite element method.

9
 Methodology
• To study literature on contact stress minimization in gear
• Design CAD models in creo parametric 2.0 of all gear
pair
• Do numerical analysis of spur gear pairs for contact stress
using Finite element analysis software ANSYS 16.0
• Manufacturing of both optimized and standard gear
• Experimental investigation of contact stresses in all spur
gear pair using photo elasticity method
• Conclude by comparing results from experimentation and
software

10
 Modeling of Involute Spur Gear
• Relation and equation
– Defining Part Parameters
– Extruding Base Feature
– Generating Involute Curve
– Sketching Tooth Space
– Patterning Tooth Space
• Assembly of Spur Gear in Mesh

11
Modeling of Involute Spur Gear

Figure: Spur Gear Assembly

12
 Finite Element Analysis

Figure : Meshing of spur gear pair Figure : Boundary conditions of ANSYS

13
 Result and discussion

Figure : Contact stresses in spur gear (φd = Figure : Effect of drive side pressure angle
35, φc = 20) on contact stress

14
 Result and discussion

Figure : Root bending stress of drive side Figure : Effect of change of root radius of
of asymmetric spur gear (φd = 35, φc = 20, drive side on bending stress of coast side of
Rf = 0.45m) gear

15
 Result and discussion

Figure : Root bending stress of coast side Figure : Effect of change of root radius of
of asymmetric spur gear (φd = 35, φc = 20, coast side on bending stress of coast side of
Rf = 0.45m) gear

16
 Conclusion
• From the given study, it is concluded that as the drive side
pressure angle of asymmetric gear increases from 20 0 to 350, all
gear pair gives decreased in contact stress of gear pair.
• For asymmetric spur gear pair with 350 drive side pressure angle
this decrement is 51.87%.
• The effect of increasing in the root radius of driving side of
asymmetric gear also lead to reduction in bending stress of gear
pair and its effect is small as 5.7%.
• The effect of increasing in the root radius of coast side of
asymmetric gear also lead to reduction in bending stress of gear
pair and its effect is about 27.4% which is larger as compare to
the effect of increasing the driving side root radius.

17
 References
• Seok-Chul Hwanga, Jin-Hwan Lee , Dong-Hyung Lee , Seung-Ho Hana,
Kwon-Hee Lee, “Contact stress analysis for a pair of mating gears”
Mathematical and Computer Modelling 57 (2013) 40–49
• Ali Raad Hassan, Contact Stress Analysis of Spur Gear Teeth Pair, World
Academy of Science, Engineering and Technology 58, (2009), pp 611–616
• Sushil Kumar Tiwari, Upendra Kumar Joshi, Stress Analysis of Mating
Involute Spur Gear teeth, International Journal of Engineering Research
and Technology. Volume 1, Issue 9, (2012), pp 1-12.
• Santosh Patil, Saravanan Karuppanan, Azmi Abdul Wahab, Contact
Pressure Evaluation of a Gear Pair along the Line of Action using Finite
Element Analysis. Applied Mechanics and Material, Vol. 393, (2013), pp
403-408.
• Santosh Patil, Saravanan Karuppanan, Ivana Atanasovska, Azmi Abdul
Wahab, Frictional tooth contact analysis along line of action of a spur gear
using Finite Element Method. Procedia Materials Science 5 (2014), pp.
1801-1809.

18
 References
• Konstandinos G. Raptis, Theodore Ν. Costopoulos, Georgios Α.
Papadopoulos and Αndonios D. Tsolakis, Rating of spur gear strength using
photoelasticity and the finite element method, American J. of Engineering
and Applied Sciences 3 (1),(2010), pp. 222-231.
• M. Rameshkumar, G. Venkatesan and P. Sivakumar, DRDO, Ministry of
Defence, Finite Element Analysis of High Contact Ratio Gear, AGMA
Technical Paper,(2010), 10FTM06.
• Kapelevich, A., “Geometry and design of involute spur gears with
asymmetric teeth”, Mechanism and Machine Theory, 2000, 35, pp. 117-
130.
• Silori, P., Shaikh, A., Kumar KC, N. and Tandon, T., “Finite Element
Analysis of Traction gear using ANSYS”, Materials Today: Proceedings,
2015, 2, pp. 2236 – 2245.
• Patil, S. S., Karuppanan, S., Atanasovska, I. and Wahab, A. A., “Contact
stress analysis of helical gear pairs, including frictional coefficients”,
International Journal of Mechanical Sciences, 2014, 85, pp. 205–211.

19
Thank you

20