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STATIC AND DYNAMIC ANALYSIS OF SPUR GEAR
A major project work in the partial fulfillment of the degree
BACHELOR OF TECHNOLOGY IN
MECHANICAL ENGINEERING
BY
B.HARISH REDDY
(07241A0387)
G.SHIVA KUMAR
(07241A0359)
Under the guidance of
RATNA KIRAN
Assistant Professor
Mechanical Department
CERTIFICATE
This is to certify that the thesis entitled
STATIC AND DYNAMIC ANALYSIS OF SPUR GEAR
Submitted by MR B.HARISH REDDY, MR G.SHIVA KUMAR in the partial fulfillment of
the requirements for the award of Bachelor of technology Degree in Mechanical Engineering
Jawaharlal Nehru Technology University, Hyderabad is an authentic work carried out by him
under my supervision and guidance. To the best of my knowledge, the matter embodied in the
thesis has not been submitted to any other University / Institute for the award of any Degree.
Internal Guide
RATNA KIRAN
Assistant Professor
Mechanical Department
GRIET
The accomplishment of this project has been lot easier owing to cooperation of Concurrent
Analysis Pt. Ltd management of Gokaraju Rangaraju Institute of Engineering and Technology.
We would like to thank the management of Concurrent Analysis Pt. Ltd for allowing us to take up
this project under them.
We would like to express our sincere thanks to our guide Mr. H.PRADEEP for helpful guidance.
We would like to express our deepest gratitude towards our guide Mr.RATNA KIRAN
(Associate Professor, Mechanical Department) for his constant help and encouragement during this
project.
We would like to thank Mr. Jandyala N Murthy (Principal, GRIET) and Mr. KGK Murthi
(HOD, Mechanical Department) for permitting us to take up this project work.
Lastly we would like to thank each and every person who helped directly or indirectly in the
successful completion of this project.
APRIL 2011
B.HARISH REDDY
G.SHIVA KUMAR
Table of figures
List of Symbols
Literature review
1.0 Introduction
1.1 Introduction to Gears
1.2 Definitions
1.2.1 Advantages
1.2.2 Disadvantages
1.3 Applications
1.4 Materials for Spur Gear
2.0 Theory
2.1 Internal Spur Gear
2.2 External spur Gear
2.3 Spur Gear Nomenclature
3.0 Mathematical equations
4.0 Finite Element Analysis
4.1 Introduction to FEA
K Structural stiffness
u Displacement vector
F Applied load vector
Pmax Maximum contact stress
d1 Pinion pitch diameter
d2 Gear pitch diameter
Fi Load per unit width
Ri Radius of cylinder i
Pressure angle
i Poissons ratio for cylinder i
Ei Youngs modulus for cylinder i
H Maximum Hertz stress.
a Contact width
r Any radius to involute curve
rb Radius of base circle
Vectorial angle at the pitch circle
Vectorial angle at the top of tooth
Pressure angle at the pitch circle
There has been a great deal of research on gear analysis, and a large body of literature on gear
modeling has been published. The gear stress analysis, the transmission errors, and the
prediction of gear dynamic loads, gear noise, and the optimal design for gear sets are always
major concerns in gear design. Errichello and Ozguven and Houser survey a great deal of
literature on the development of a variety of simulation models for both static and dynamic
analysis of different types of gears. The first study of transmission error was done by Harris.
He showed that the behavior of spur gears at low speeds can be summarized in a set of static
transmission error curves. In later years, Mark and analyzed the vibratory excitation of gear
systems theoretically. He derived an expression for static transmission error and used it to
predict the various components of the static transmission error spectrum from a set of
measurements made on mating pair of spur gears. Kohler and Regan discussed the derivation
of gear transmission error from pitch error transformed to the frequency domain. Kubo et al
estimated the transmission error of cylindrical gears using a tooth contact pattern. The current
literature reviews also attempt to classify gear model into groupings with particular relevance
to the research. The following classification seems appropriate:
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Spur Gears are the most common means of transmitting power in the
modern mechanical engineering world. They vary from tiny size used in
the watches to the large gears used in marine speed reducers; bridge lifting
mechanism and railroad turn table drivers. They form vital elements of
main and ancillary mechanism in many machines such as automobiles,
tractors, metal cutting machine tools, rolling mills, hoisting and
transmitting machinery and marine engines etc.
The four major failure modes in gear systems are tooth bending fatigue,
contact fatigue, surface wear and scoring. Two kinds of teeth damage can
occur on gears under repeated loading due to fatigue; namely the pitting of
gear teeth flanks and tooth breakage in the tooth root. Tooth breakage is
clearly the worst damage case, since the gear could have seriously
hampered operating condition or even be destroyed. Because of this, the
stress in the tooth should always be carefully studied in all practical gear
application. The fatigue process leading to tooth breakage is divided into
crack initiation and crack propagation period. However, the crack initiation
period generally account for the most of service life, especially in high
cycle fatigue.
The initial crack can be formed due to various reasons. The most
common reasons are short-term overload, material defects, defects
due to mechanical or thermal treatment and material fatigue. The
initial crack then propagates under impulsive loading until some
critical length is reached, when a complete tooth breakage occurs.
The service life of a gear with a crack in the tooth root can be
determined experimentally or numerically (e.g. with finite element
method). The fatigue life of components subjected to sinusoidal
loading can be estimated by using cumulative damage theories.
Their extension to random load fatigue, through straightforward,
may not be very accurate owing to inherent scatter exhibition by the
fatigue phenomena. Due to the complexity in geometry and loading
on the structure, the finite element method is preferably adopted.
1) MODULE:
Module of a gear is defined as ratio of diameter to number of teeth.m= d/N
2) FACE WIDTH
The width along the contact surface between the gears is called the face width.
3) TOOTH THICKNESS
The thickness of the tooth along the pitch circle is called the tooth thickness.
4) ADDENDUM
The radial distance between the pitch circle and the top land of the gear is called the
addendum.3
5) DEDENDUM
The radial distance between the pitch circle and the bottom land of the gear is called the
dedendum.
6) PRESSURE ANGLE
The angle between the line joining the centers of the two gears and the common tangent to the
base circles.
1.2.1 ADVANTAGES
` Gear is one kind of mechanical parts. It can be widely used in industries. A
gear is a rotating machine part having cut teeth, or cogs, which mesh with
another toothed part in order to transmit torque.
` Spur gear is the simplest type of gear which consists of a cylinder or disk. Its
form is not straight-sided, thus, the edge of each tooth is straight and aligned
parallel to the axis of rotation. Only gears fit to parallel axles can they rotate
together correctly.
` As the most common type, spur gears are often used because they are the
simplest to design and manufacture. Besides, they are the most efficient. When
compared to helical gears, they are more efficient. The efficiency of a gear is
the power output of its shaft divided by the input power of its shaft multiplied
by 100. Because helical gears have sliding contact between their teeth, they
produce axial thrust, which in turn produces more heat. This causes a loss of
power, which means efficiency is lost.
` In addition to these, they also have many other advantages. Spur gears have a
much simpler construction than helical gears because their teeth are straight
rather than angular. Therefore, it is much easier to design and produce them.
And they will not fail or break easily. And this makes them cheaper to
purchase and to maintain which then leads to less cost.
Simplicity
Because their teeth are straight rather than angular, spur gears have a much
simpler construction than helical gears. As such, they are easier to produce, and
they tend not to break or fail as easily. This also makes them easier to find.
Efficiency
Spur gears are more efficient than helical gears. The efficiency of a gear is
the power output of its shaft divided by the input power of its shaft multiplied by
100. Because helical gears have sliding contact between their teeth, they produce
axial thrust, which in turn produces more heat. This causes a loss of power, which
means efficiency is lost.
Cost
Because spur gears are simpler, they are easier to design and manufacture, and
they are less likely to break. This makes them cheaper to purchase and to maintain.
1.2.3DISADVANTAGES
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Although they are common and efficient, spur gears have disadvantages as
well. Firstly, they are very noisy when used at some speeds because the
entire face engages at once. Therefore, they're also known as slow-speed
gears. Secondly, they can only be used to transfer power between parallel
shafts. They cannot transfer power between non-parallel shafts. Thirdly,
when compared with other types of gears, they are not as strong as them.
They cannot handle as much of a load because the teeth are small and
situated parallel to the gear axis, rather than being large and situated
diagonally as the teeth on a helical gear are.
According to the above, we can conclude that spur gears have many
advantages as well as some disadvantages. Although sometimes, its
disadvantages may affect them a lot, their advantages still outweigh their
disadvantages. That is to say, spur gears are still popular among many
industries. And they can have good performances to meet people's
requirements
The image shows a Spur Gear and Plastic Spur Gears used in a
film winding component.
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As is clear from the figure the gear tooth are cut from inside. A
typical Internal Spur Gear or Ring Gear consists of typically three or
four larger spur gears referred to as planets. That surrounds a
smaller central pinion referred to as sun. Normally, the ring gear
remains stationary. This is quite like our own Planetary system,
where the planets orbit round the sun in the same rotational
direction. It is quite obvious that this class of gear is known as a
planetary system. It is through a planet carrier that transmits the
orbiting motion of the planets to the output shaft.
External Spur Gears are the most popular and common type of spur gear. They has
their teeth cut on the outside surface of mating cylindrical wheels. While the larger
wheel is referred to as the gear and the smaller wheel is known as the pinion. Single
reduction stage is the most basic type of arrangement of single pair of spur gears.
Here the output rotation is in opposite direction to that of the input. In other
arrangements of multiple stages higher net reduction can be achieved where the
driven gear is connected rigidly to a third gear. This third gear in turn drives a
mating fourth gear. This serves as the ideal output for the second stage. In
this way, many output speeds on different shafts are produced starting from
a just single input rotation. The image given below shows the inside of
External Spur Gears.
Actually the working of External Spur Gear is best explained with the help
of Gear meshes. In the external mesh, the gears are made to rotate in
directions that are opposite. The Figure below shows a simple spur gear
mesh where the gears are meshing externally.
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When the gear transmits the power P, the tangential force produced due to
the power is given by
Ft = (PxKs/v)
V = (xDpxNp) / (60x1000)
= (x357.4x3500)/(60000)
= 65.51 m/s
Ft = (9000x103x2)/65.51
=274749.26
4.1Introduction
The Basic concept in FEA is that the body or structure may be
divided into a smaller elements of finite dimensions called Finite
Elements. The original body or the structure is then considered as
an assemblage of these elements connected at a finite number of
joints called Nodes or Nodal Points. Simple functions are
chosen to approximate the displacements over each finite element.
Such assumed functions are called shape functions. This will
represent the displacement with in the element in terms of the
displacement at the nodes of the element.
The Finite Element Method is a mathematical tool for solving
ordinary and partial differential equations. Because it is a numerical
tool, it has the ability to solve the complex problems that can be
represented in differential equations form. The applications of FEM
are limitless as regards the solution of practical design problems.
Due to high cost of computing power of years gone by, FEA has a history
of being used to solve complex and cost critical problems. Classical
methods alone usually cannot provide adequate information to determine
the safe working limits of a major civil engineering construction or an
automobile or an aircraft.
In the recent years, FEA has been universally used to solve structural
engineering problems. The departments, which are heavily relied on this
technology, are the automotive and aerospace industry. Due to the need to
meet the extreme demands for faster, stronger, efficient and lightweight
automobiles and aircraft, manufacturers have to rely on this technique to
stay competitive.
FEA has been used routinely in high volume production and manufacturing
industries for many years, as to get a product design wrong would be
detrimental. For example, if a large manufacturer had to recall one model
alone due to a hand brake design fault, they would end up having to replace
up to few millions of hand brakes. This will cause a heavier loss to the
company.
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The finite element method is a very important tool for those involved in
engineering design, it is now used routinely to solve problems in the
following areas.
Structural analysis
Thermal analysis
Vibrations and Dynamics
Buckling analysis
Acoustics
Fluid flow simulations
Crash simulations
Mold flow simulations
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The first two steps of the above said process is known as pre-processing
stage, third and fourth is the processing stage and final step is known as
post-processing stage.
What is an Element?
Element is an entity, into which a system under study can be divided into.
An element definition can be specified by nodes. The shape(area, length,
and volume) of the element depends upon the nodes with which it is made
up of.
0-D Element :
This has the shape of the point, it requires only one node to define it
1-D Element :
This has the shape of the line/curve and hence requires minimum of two
nodes to define it.
2-DElement:
This is an n area element, which has the shape of the quadrilateral/triangle
and hence requires minimum four/three nodes to define it.
3-DElements:
This is a volume element, can take the shape of a Hexahedron or a Wedge
or a Tetrahedron. Hexahedron element requires 8 nodes to define its shape.
A Penta element requires 6 nodes to define its shape. Similarly 4 nodes are
Associativity
Associatively is a term that is used to indicate geometric
relationships between individual portions of a model. These
relationships are established as the designer uses various functions
for model creation. In an associative model, constraints and
relationships are captured automatically as the model is developed.
For example, in an associative model, a through hole is associated
with the faces that the hole penetrates. If the model is later changed
so that one or both of those faces moves, the hole updates
automatically due to its association with the faces. See Introduction
to Feature Modeling for additional details.
Positioning a Feature
Within Modeling, you can position a feature relative to the
geometry on your model using Positioning Methods, where you
position dimensions. The feature is then associated with that
geometry and will maintain those associations whenever you edit
the model. You can also edit the position of the feature by changing
the values of the positioning dimensions.
Reference Features
You can create reference features, such as Datum Planes, Datum Axes and
Datum CSYS, which you can use as reference geometry when needed, or
as construction devices for other features. Any feature created using a
reference feature is associated to that reference feature and retains that
association during edits to the model. You can use a datum plane as a
reference plane in constructing sketches, creating features, and positioning
features. You can use a datum axis to create datum planes, to place items
concentrically, or to create radial patterns.
Expressions
The Expressions tool lets you incorporate your requirements and design
restrictions by defining mathematical relationships between different parts
of the design. For example, you can define the height of a extrudes as three
times its diameter, so that when the diameter changes, the height changes
also.
The strategy you use to create and edit your model to form the desired
object depends on the form and complexity of the object. You will likely
use several different methods during a work session. The next several
figures illustrate one example of the design process, starting with a sketch
and ending with a finished model. First, you can create a sketch "outline"
of curves. Then you can sweep or rotate these curves to create a complex
portion of your design.
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It lets the NC programmer generate fully associative tool paths for models
for which the programmer may not have write access privilege.
6.1Gear Analysis
` The objective of the analysis is to perform Structural static
analysis on the gear by applying tangential load and examine
the deflections and stresses and calculate the factor of safety.
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The parasolid file is imported into ansys and is meshed with 8 node solid45
element type. The structure, number of nodes and input summary of the
element is given below.
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Aluminum
Youngs Modulus = 3.4 E4 N/mm2
Poissons Ratio = 0.22
Ultimate tensile strength = 260 N/mm2
Yeild strength = 165 N/mm2
Boundary Condition
Tangential Load along x-axis = 274749N
Centre shaft location is arrested in all DOF.
Results and discussion:
You use modal analysis to determine the natural frequencies and mode
shapes of a structure. The natural frequencies and mode shapes are
important parameters in the design of a structure for dynamic loading
conditions. They are also required if you want to do a spectrum analysis or
a mode superposition harmonic or transient analysis.
You can do modal analysis on a prestressed structure, such as a spinning
turbine blade. Another useful feature is modal cyclic symmetry, which
allows you to review the mode shapes of a cyclically symmetric structure
by modeling just a sector of it.
First 10 natural frequencies have been calculated for the gear model using
modal analysis.
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Aluminum
Youngs Modulus = 3.4 E4 N/mm2
Poissons Ratio = 0.22
Density = 2700 kg/mm3
Ultimate tensile strength = 260 N/mm2
Yeild strength = 165 N/mm2
Element Type: 8 node Solid 45
Shape of the element: Hexahedral
No. of .dof: 3(ux, uy, uz)
Results & Discussions:
First 10 Natural frequencies
Mode-5
Mode7:
Mode9:
The harmonic analysis is performed on the gear between the range of 500
to 1600Hz and the structure behavior at different frequencies is observed
due to applied tangential load of 274947N.
Any sustained cyclic load will produce a sustained cyclic response (a
harmonic response) in a structural system. Harmonic response analysis
gives you the ability to predict the sustained dynamic behavior of your
structures, thus enabling you to verify whether or not your designs will
successfully overcome resonance, fatigue, and other harmful effects of
forced vibrations.
Harmonic response analysis is a technique used to determine the steadystate response of a linear structure to loads that vary sinusoidally
(harmonically) with time. The idea is to calculate the structure's response at
several frequencies and obtain a graph of some response quantity (usually
displacements) versus frequency. "Peak" responses are then identified on
the graph and stresses reviewed at those peak frequencies.