COMPUTER AIDED ANALYSIS OF INVOLUTE GEAR TOOTH FOR MINIMIZATION OF BENDING STRESS

UNDER THE GUIDANCE OF Sri

.P. SRINIVAS
BY

ASSOCIATE PROFESSOR G.I.T.A.M COLLEGE OF ENGINEERING.VISAKHAPATNAM.

P. RAMA KRISHNA
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CONTENTS
     ABSTRACT INTRODUCTION OF GEARS LITERATURE SURVEY INTRODUCTION OF FEM GEOMETRIC MODELLING AND ANALYSIS OF GEAR TOOTH    RESULTS AND DISCUSSIONS CONCLUSIONS REFERENCES
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ABSTRACT
 Sufficiency in bending load carrying capacity is a serious problem, as regards the carburized or surface quality improved gears with very high surface fatigue strength, such as plastic and sintered gears.

There are several ways to solve the problem such as heat treatments, improving tooth fillet surface quality, and using a larger radius of cutters tip corner.

The load carrying capacity of transmissions can also be increased by modifying the involute geometry. However, an additional alteration though rarely used, is to make the gears asymmetric with different pressure 3 angles for power side of the tooth. Contd.,

The aim of asymmetric tooth is to improve the performance of gears such as increasing the load carrying capacity consequently decreasing the bending stresses thereby increasing the durability for the drive side of the tooth.  The involute profile of gear teeth is modeled and the analysis part is carried by using ANSYS software. The effect of asymmetric gears with greater pressure angle on the drive side than coast side pressure angle has been analyzed.


In addition to the above modifications, it has also been shown that bending stresses can also be reduced by altering the root fillet radius.  The decreasing of bending stress makes it possible to manufacture small gears, in other words lighter ones.  This advantage gives wider application of gears in aerospace and automotive industries.
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INTRODUCTION OF GEARS
The strength of a gear depends on the bending stress  of the gear teeth. The bending stress can be calculated using the most popular and dependable equation developed by Lewis and called after his name as Lewis Equation. This is used for finding the static strength of the gear tooth.

GEAR TERMINOLOGY

FORMS OF TEETH

Different forms of teeth are used for the profile of gear teeth. They are Cycloidal teeth Involute teeth

Construction of cycloidal teeth of gear.

Construction of involute teeth

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Advantages of Involute Gears

The centre distance for a pair of involute gears can be varied within limits without changing the velocity ratio. In involute gears, the pressure angle, from the start of the engagement of teeth to the end of the engagement, remains constant. It is necessary for smooth running and less wear of gears. The involute teeth are easy to manufacture than cycloidal teeth. In involute system, the basic rack has straight teeth and the same can be cut with simple tools.
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 SYSTEMS OF GEAR TEETH

The following four systems of gear teeth are commonly used in practice.  14 degree Composite system.  14 degree Full depth involute system.  20 degree Full depth involute system.  20 degree Stub involute system.

INTERFERENCE IN INVOLUTE GEARS

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BEAM STRENGTH OF GEAR

TEETH LEWIS EQUATION

GEAR TOOTH UNDER LOAD

Ww = M. y / I
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LITERATURE SURVEY
Kadir Cavdar [1] has presented a method for the determination of bending stress minimization of involute spur gears Alexander Kapelevich [2], suggested a method that enables to increase the load capacity, reduce weight, size and vibration level and the findings of his research in this direction are as follows. The asymmetric tooth geometry allows for an increase in load capacity while reducing weight and dimensions for some types of gears. It becomes possible by increasing of pressure angle and contact ratio for drive side. Faydor L. Litvin [3] discussed about asymmetric spur gear drives in which, according to them the asymmetry means that larger and smaller pressure angles are applied for the driving and coast sides respectively.
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Alexander et al. [4] discussed bending stress minimization by changing fillet radius and given the following conclusions. Bending stress balance allows equalizing the tooth strength and durability for the pinion and the gear. Optimization of the fillet profile allows reducing the maximum bending stress in the gear tooth root area by 10 to 30 %. It work equally well for both symmetric and asymmetric gear tooth profiles. Roderick E. Kleiss, Dr. Alexander L. Kapelevich [5] discussed about an alternative method of analysis and design of spur and helical involute gears Direct gear design allows analysis of a wide range of parameters for all possible gear combinations in order to find the most suitable solution for a particular application. This optimum gear solution can exceed the limits of traditional rack generating methods of gear design.
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Thomas M. Mc Namara, Alexander L. Kapelevich [6] discussed about an alternative method of analysis and design of involute gears which separates gear geometry definition from tool selection to achieve the best possible performance for a particular product and application. This method has successfully been applied for a number of automotive applications. Direct gear design results in a 15-30% reduction in stress level when compared to traditionally designed gears. This reduction can be translated into, increased load capacity (15-30%), Size and weight reduction (10-20%), longer life, Cost reduction, increased reliability, noise and vibration reduction, increased Gear efficiency and Maintenance cost reduction.
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GENERAL PROCEDURE FOR SOLVING A PROBLEM BY FEM

Model Building Discretization of the domain Size of the element Number of elements Elements assumed

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CRITERIA OF FINITE ELEMENTS SELECTION

The number and type of elements to be used is dependent on physical problem itself. The following are important considerations in selection of type of element. The number and degrees of freedom required. The expected accuracy. Ease of developing the governing equation. The degree to which the physical structure can be modeled without approximation.

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TYPES OF ELEMENTS

Truss & Beam Elements  Plane Stress & Plane Strain Element Three Dimensional Elements

Analysis Types

 

Static Analysis Dynamic Analysis

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GENERAL PROCEDURE OF THE FINITE ELEMENT METHOD

Descretize the given continuum. Select the solution approximation Develop element matrices and equations Assemble the element equations Solve for the unknowns at the nodes Interpreting the results
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GEOMETRIC MODELING AND ANALYSIS OF GEAR TOOTH

Alternative I TO MINIMIZE THE BENDING STRESS IN THE GEAR TOOTH, THE ASYMMETRIC GEAR TOOTH IS CONSIDERED AS FIRST ALTERNATIVE DESIGN. INPUT PARAMETERS Gear Ratio = 10: 1 Distance between centers = 660 mm, No. of teeth on gear = 150, Module (m) = 8 mm, Pitch circle diameter = 1200 mm,
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GEOMETRIC MODELING AND ANALYSIS OF GEAR TOOTH

Theoretical calculations The following formulae are used to calculate bending stress. The maximum value of the bending stress (or the permissible working stress), at the section BC is given by Bending = M y / I = ( WT * h ) t/2 b t*t*t / 12 = ( WT * h ) 6 b t*t

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GEOMETRIC MODELING AND ANALYSIS OF GEAR TOOTH

From the Constructional Geometry we get thickness at the dedendum. t = 23.09 mm 1. For pressure angle of 200 - 200 : h= 10.01 mm 2. For pressure angle of 200 - 250 : t = 24.43 mm h = 10.01 mm 3. For pressure angle of 200 - 300 : t = 24.89 mm h = 10.01 mm 4. For pressure angle of 200 - 350 : t = 25.82 mm h = 10.01 mm 5, For pressure angle of 200 - 400 : t = 27.19 mm h = 10.01 mm 6. For pressure angle of 200 - 450 : t = 28.54 mm h = 10.01 mm
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Theoretical calculations for 20-20. Force applied W = 50 N Now Resolution of force in Wt = W* Cos 20 = 50 * Cos 20 = 46.98 N Wr = W * Sin 20 = 50 * Sin 20= 17.10 N
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Bending stress calculation

Bending stress equation
Bending

= (Wt * h * 6) / ( b * t *t )

Here h = 10 mm b = 40 mm t = 23.09 mm
Bending

= ( 46.98 * 9.81* 10 * 6) / (40 * 23 * 23 ) = 1.29 kgf / mm2

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Involute profile of gear teeth when pressure angles are 20&20deg.

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Analysis of Involute profile of gear teeth when pressure angles are 20&20deg.

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3D View:

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Involute profile of gear teeth when pressure angles are 20 & 25deg.

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Analysis of Involute profile of gear teeth when pressure angles are 20&25deg.

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Involute profile of gear teeth when pressure angles are 20&30deg.

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Analysis of Involute profile of gear teeth when pressure angles are 20&30deg.

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Involute profile of gear teeth when pressure angles are 20&35deg.

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Analysis of Involute profile of gear teeth when pressure angles are 20&35deg.

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Involute profile of gear teeth when pressure angles are 20&40deg.

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Analysis of Involute profile of gear teeth when pressure angles are 20&40deg.

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Involute profile of gear teeth when pressure angles are 20&45deg.

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Analysis of Involute profile of gear teeth when pressure angles are 20&45deg.

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Percentage change in bending stress

Pressure Angle ( )in degrees 20 -20 20 - 25 20-30 20-35 20-40 20-45

Stress ( ) in Kgf /mm2 1.09 0.975 0.874 0.814 0.756 0.629

% reduction in b Reference 10.5% 20.18% 25.32% 31.19% 42.29%

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Comparison of theoretical and calculated stresses

S.N O. 1 2 3 4 5 6

Pressure angle ( ) in degrees 20-20 20-25 20-30 20-35 20-40 20-45

Theoretical Stress( Bending ) Kgf/mm2 1.290 1.117 1.027 0.904 0.762 0.638

Stress shown by ANSYS Kgf/mm2 1.090 0.975 0.875 0.814 0.756 0.629
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Alternative II: Minimization of Bending stress in the gear tooth by modifying the root fillet.

Keeping all parameters of alternative-1 except the fillet radii, an attempt is made to explore the possibility of obtaining better bending stresses by suitable curve fitting method. (Best curve fit method) Bending stress minimization is the result of the definition of the fillet profile that provides minimum bending stress concentration and satisfies certain conditions (eg. manufacturability). They are based on a curve fitting technique when the trochoid filet profile, typical for the rack or mating gear generative method, is replaced by a parabola, ellipsis, chain line, or other curve reducing the bending stress.

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Involute profile of symmetric gear tooth with designed fillet:

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Analysis of involute profile of symmetric gear tooth with designed fillet.

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Involute profile of symmetric gear tooth modified with circular root fillet:

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Analysis of involute profile of symmetric gear tooth modified with circular root fillet:

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Involute profile of symmetric gear tooth modified with Elliptical-1 root fillet:

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Analysis of involute profile of symmetric gear tooth modified with Elliptical-1 root fillet:

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Involute profile of symmetric gear tooth modified with Elliptical-2 root fillet:

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Analysis of involute profile of symmetric gear tooth modified with Elliptical-2 root fillet:

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Bending stresses at different root filet shape of 200 involute symmetric teeth.

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Results and Discussions:

Contd.,
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Contd.,
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Conclusions

In the suggested alternative -1, in which the asymmetric teeth are considered with increased pressure angle on the drive side from 200 - 200 to 200 - 450 , it is noted that the bending stresses in the gear tooth is reduced by 42.29 %. As the pressure angle on the drive side is further increased beyond 450 the top land of the tooth is narrowed and finally resulted in a single line because of intersection of the two involute profiles on either side of the tooth. In the suggested alternative- 2, it is observed that the bending stresses are reduced by 48.51% when the fillet radius is elliptical. From the two alternatives, it is found that the alternative- 2 is better option to employ in the manufacture of gears for reduced bending stresses by employing the modified fillet radius.
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REFERENCES
       [1] Kadir Cavdar, Fatih Karpat and Fatih C. Babalik, Computer aided analysis of bending strength of involute spur gears with asymmetric profile. Journal of mechanical design, May 2005, volume 127/477-484. [2] Alexander L. Kapelevich and Yuriy V. shekhtman, Direct gear design: Bending stress minimization , Gear technology, sep/oct-2003, pg.No.s 44-48 [3] Alexander L. Kapelevich and Thomas M.Mc Namara, Direct gear design for automotive applications, 2005 SAE International paper 05p-149. [4] Alexander L. Kapelevich and Roderick E.Kleiss, Direct gear design for spur and Helical Involute gears , Gear technology, sep/oct 2002- pg.No.s29-36 [5] Alexander L. Kapelevich Geometry and design of Involute spur gears with asymmetric teeth . [6] Faydor L. Litvin, Qiming Lian, Alexander L. Kapelevich Asymmetric modified spur gear drives: reduction of noise, localization of contact, simulation of meshing and stress analysis, Computer methods in applied mechanics and 53 Engineering 188 (2000) pg.No.363-390.

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