International Journal of Engineering Trends and Technology (IJETT) – Volume 34 Number 4- April 2016
Material optimization of high speed single
helical gear by using fea approach
Parth J. Bhatt#1, Assi. Prof. Pranav B. Bhatt
#2
#1
PG student, department of mechanical engineering
Noble group of institute
Junagadh - 362 001, India
#2
Assistant Professor, department of mechanical engineering
Noble group of institute
Junagadh - 362 001, India
Abstract - Gears are one of the most critical components in
mechanical power transmission systems. In this paper high
speed helical gear used in planner machine will be
analyzed. 3D models of high speed helical gear will be
generated by modeling software and simulation will done by
finite element software package. The bending stress of the
gear tooth are consider to be one of the main contributors
for the failure of the gear in gear set. Stresses found out is
root bending stress. This paper investigates finite element
model for monitoring the stresses induced in tooth flank,
tooth fillet during meshing of gear. Load is applied on the
tip of the tooth and bending stresses are occur on the root of
the tooth. stresses are found out for different material.
Analytically it can be validated by using Lewis and AGMA
bending equation. Study will be conducted by varying face
width to find stress.
Keywords—bending stress, AGMA equation, fea
approach, Lewis equation, alluminium alloy, grey cast
iron.
I. INTRODUCTION
technology. Helical gears offer a refinement over spur
gear. The leading edge of the teeth of
II. LETRATURE REVIEW
A. Compative study of stress analysis of helical
gear using AGMA standards and FEM:
Tribhuvan Singh and Mohd.parvez[1] has done
modification in high speed helical gear for
reduction of bending stress and contact stress. In
this work three dimensional solid model has been
generated in pro engineer and then the model is
imported in ansys 11.1 for finding bending stress
and contact stress. The face width and helix angle
are the varied for reduction of stresses for deferent
number of teeth. The validation of method is done
by AGMA formula for bending stress and hertz’s
contact stress formula for contact stress.
B. Analysis of bending strength of helical gear by
FEM:
Kailash C. Bhosale[2] has found bending
stress by lewis equation for helical gear. The
accurate evaluation of stress state and distribution
of stress is complex task. The stresses produced at
any discontinuity are different in magnitude from
those calculated by elementary formulae. Bending
stress is also found out by ANSYS and then they
are compared. Result were match each other.
C. Design and structural analysis of high speed
helical gear using ansys:
FIG 1:HELICAL GEAR
One of the best methods of transmitting
power between the shafts is gears. Gears are mostly
used to transmit torque and angular velocity. The rapid
development of industries such as vehicle, shipbuilding
and aircraft require advanced application of gear
ISSN: 2231-5381
J. Venkatesh and Mr. P.B.G.S.R.
Murthy[3] has done structural analysis of high
speed helical gear using FEA approach. root
bending stress has been found in ansys. Lewis
beam strength method is used then both results are
compared.
D. Modeling and Analysis of Spur Gear for
Sugarcane Juice Machine under Static
Load
Condition by Using FEA:
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International Journal of Engineering Trends and Technology (IJETT) – Volume 34 Number 4- April 2016
V. Siva Prasad, Syed Altaf Hussain, V.
Pandurangadu and K. PalaniKumar[4] has done
analysis of spur gear used in sugarcane juice
machine using FEA approach. In this work the 3D
Model of spur gear is created in pro e and analysis
is done in ansys 10.0 for deferent material.
Metallic material which is tried is cast iron and
plastic material which is tried is nylon
polycarbonate plastic material.Analysys is for
replacing the material to reduce the weight of
current gear.
E. Comparative finite element analysis of metallic
spur gear and hybrid spur gear:
V. FEA ANLYSIS OF HELICAL GEAR
Finite element analysis of helical gear is done by
means of ansys workbench 15.0.Bending stress of
helical gear is found for deferent material and
analytically it can be validated by using AGMA and
lewis formulas.
A. boundary condition
Load is applied at the tip of the tooth 889 N.
Support applied is fixed support. Maximum principal
stress is found out.
B. Finding stress for different material:
Sanjay K. Khavdu and Prof. Kevin M. Vyas[5]
has done work for reduce weight of gear
mechanism
by
checking
possibility
of
replacement of all metallic gears with composite
hybrid gears in that gear mechanism. In this work
weight calculation is done using ANSYS
workbench v11.Bending stress induced in gear is
compared for both case by AGMA and ansys.
TABLE I:SPECIFICATION OF GEAR
Sr. no.
Parameter
Gear
1
2
3
4
5
6
7
8
Number of teeth
Pressure angle
Helix angle
Face width (mm)
Normal module (mm)
Diameter of pitch circle (mm)
Diameter of base circle (mm)
Diameter of addendum circle
(mm)
Diameter of Dedendum circle
(mm)
Young’s modulus (MPa)
Poisson’s ratio
Density (kg/m3)
36
9
10
11
12
(LH)
40
4
144
135.2
152
FIG 2: BENDING STRESS FOR STEEL
MATERIAL
As shown in the figure for steel material we can
find maximum bending stress as 23.354 MPa
134
2.1×105
0.3
7850
IV SPECIFICATION OF MATERIALS USED:
In existing helical gear steel is used which has
with IS standard 1570-4(1988) with chemical
composition 0.45% carbon,0.35% silicon,0.70%
mangenese,1.75% nickel, 1.30% chromium,0.35%
molybdenum.
Material tried using ansys is alluminum
alloy with IS standard 733 (2008) with chemical
composition 98% aluminum , 0.2% copper, 0.1%
magnesium ,
0.6% silicon, 0.6% iron,0.1%
manganese, 0.2% zinc.
TABLE II: PROPERTIES OF MATERIALS
Material
steel
aluminum alloy
Poisson's ratio
0.3
0.220
Young's
2.1×105
3.4×105
modulus(MPa)
Density(Kg/m3)
7850
3900
Bending
392
350
strength(N/mm2)
ISSN: 2231-5381
FIG 3: BENDING STRESS FOR ALUMINIUM
ALLOY MATERIAL
As shown in the figure for alluminium
material stress is 23.5 MPa.
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International Journal of Engineering Trends and Technology (IJETT) – Volume 34 Number 4- April 2016
TABLE III:COMPARISION OF ANSYS STRESS VALUES
FOR DIFFERENT MATERIAL:
Material
Root bending stress (MPa)
LEWIS
AGMA
ANSYS
steel
22.56
23.16
23.354
alluminium
alloy
22.56
23.16
23.500
VI. CONCLUSION
In this work stress analysis of high speed helical
gear is done for different material. Bending stress is
found out by fea software package ansys 15.0 and It
is analytically validated by AGMA and Lewis
equation. By analysis it can be found that no more
stress changes for different material. stress occur is
within safety limits.So aluminum is selected as the
best material for less corrosion resistance, less weight
and less cost than other material.
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“Analysis of bending strength of helical gear by FEM” by
Kailash C. Bhosale published in
Innovative Systems
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“Design and structural analysis of high speed helical gear
using ansys” by J. Venkatesh, Mr. P. B. G. S. N. Murthy
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“Modeling and Analysis of Spur Gear for Sugarcane Juice
Machine under Static Load Condition by Using FEA” by V.
Siva Prasad, Syed Altaf Hussain, V.Pandurangadu, K.Palani
Kumar published in International Journal of Modern
Engineering Research Vol.2, Issue.4, 2012.
“Comparative finite element analysis of metallic spur gear
and hybrid spur gear” by Sanjay K. Khavadu, Kevin M.
Vyas
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