Workbook

Swinburne University of Technology (Sarawak
Campus)
Faculty of Engineering, Computing and Science

MEE40008 Final Year Research Project 2 (Mechanical)
Project Logbook
Author: Supervisor:
Ibrahim Hussaini (4241606) Dr. Soon Kok Heng
November 18, 2016

Project Logbook Ibrahim Khalil Hussaini (4241606)
1 Simulations undertaken
1.1 Model A
Figure 1: Geometry of Model A.
Figure 2: Model A meshed.
Page 1
1.1.0.1 Fatigue
Figure 3: Equivalent von-Mises (Kf=1.0)
Page 2
Page 3
Figure 7: Max shear (Kf=1.0)
Page 4
Page 5
1.2 Model B
Figure 11: Geometry of Model B
Page 6
Figure 12: Contact settings for Model B
Page 7
Figure 13: Model B meshed
Figure 14: Model B boundary conditions
Page 8
Figure 15: Model B equivalent von-Mises stress
Figure 16: Model B safety factor
Page 9
1.2.0.1 Fatigue
Page 10
Page 11
Page 12
Page 13
Page 14
1.2.1 Friction
Figure 25: Equivalent von-Mises stress ( = 0)
Page 15
Figure 26: Equivalent von-Mises stress ( = 0.01)
Page 16
Page 17
Page 18
1.3 Model C
Figure 31: Geometry of Model C
Page 19
Figure 32: Contact conditions of Model C
Figure 33: Mesh of Model C
Page 20
Figure 34: Boundary conditions of Model C
Figure 35: Model C Equivalent von-Mises stress
Page 21
1.3.0.1 Fatigue
Page 22
Page 23
Page 24
Page 25
Page 26
Supervisor Name Date & Signature
Page 27
2 Week 2
2.1 Description of activities
Monday
1. Researched on the fundamentals of gear contact stresses.
2. Researched about the parameter to be analyzed which is contact ratio.
3. Researched on how the variation in contact ratio affects gear contact stress
Tuesday
1. Meeting with supervisor for further discussions about the topic
Instructed to conduct research on contact stress computational models.
To research about possible research gaps regarding my topic in order to identify the research
outcomes and objectives.
Supervisor also emphasized to do adequate readings and research in other to understand
optimally the whole idea about the research topic.
Explained how to go about conducting the experiment in ANSYS with respect to model
setup and boundary conditions.
Wednesday
1. Researched on how contact stress and bending stress play a significant role in the design of gear
after reading through:
International Journal of Engineering Research & Technology (IJERT) with title Stress
Analysis of Mating Involute Spur Gear Teeth.
Thursday
1. Studied the the paper Stress Analysis of Composite Spur Gear
Understood from the above paper that conducted research on the static stress characteristics
of an involute composite spur gear system including bending stresses and contact stresses
of gears in mesh and comparing it with the existing involute cast iron spur gear system.
The objective of the work was to replace the cast iron spur gear with carbon fibre epoxy
composite spur gear.
The paper concluded that the cast iron spur gear can be replaced by Carbon fiber re-
inforced epoxy (composite) spur gear due to its high strength, low weight and damping
characteristics.
Page 28
Friday
1. Further literature reading on contact ratio behaviors.
Studied the the paper Finite element modeling and bending stress analysis of non standard
spur gear
Understood from the above paper that conducted research on non standard that the as-
sessment of pressure angle modification on drive side leads to interesting conclusions.
It was observed that while the pressure angle modification affects the gear tooth geometry,
the modification study is itself limited by gear parameters.
It was observed that the pressure angle has insignificant influence on the induced stress
whereas the contact stress is considerably reduced by decreasing the pressure angle.
It was observed that the shape of the tooth becomes more pointed or peaked and the tooth
flank becomes more curved.
I understood that the asymmetric tooth geometry allows for an increase in load carrying
capacity while reducing the weight and dimensions for gears.
Page 29
3 Week 3
Monday
1. Preparing for the meeting with my supervisor, while documenting progress made on the under-
standing of the research topic.
Tuesday
1. Documenting down the list of questions and clarifications needed prior to the meeting with the
supervisor
2. Studied through the thesis named Stresses and deformations in involute spur gears by finite
element method
In this journal I understood how the variations of the whole gear body stiffness arising
from the gear body rotation due to bending deflection, shearing displacement and contact
deformation.
I also understood that mesh stiffness variation as the number of teeth in contact changes
is the primary cause of excitation of gear vibration and noise.
Discovered that in order to handle contact problems in meshing gears with the finite element
method, the stiffness relationship between the two contact areas is usually established
through a spring that is placed between the two contacting areas. This can be achieved by
inserting a contact element placed in between the two areas where contact occurs.
Page 30
Wednesday
1. Meeting with the supervisor
Presented the progress I have made on my research and asking clarifications on some un-
derstandings acquired.
Discussed with the supervisor for further areas I should concentrate on while carrying out
my research.
Discussed on the recommended methodology approach I should follow for the entire research
project.
The supervisor asked me to focus on relevant recent literature as obtained on online
databases duch as science direct, Scopus and Google scholar.
The supervisor committed to help me to obtain the softwares needed for the research.
Thursday
1. Studied through the journal Modeling and finite element analysis of spur gear
This research focuses on stress analysis of mating teeth of spur gear to find maximum
contact stress in the gear teeth.
I found out from this journal that the results from both Hertz equation and Finite Element
Analysis are comparable.
I also found out that Finite Element Method is the easy technique as compared to the
theoretical methods to find out the stress developed in a pair of gears.
I discovered that Fixed support is applied on inner rim of the lower gear. Frictionless
support is applied on the inner rim of upper gear to allow its tangential rotation but
restrict from radial translation.
Friday
1. Studied through the tutorial on Gear Modeling with Addendum Modification coefficient in
siemens plm nx 10.
Page 31
4 Week 4
Monday
1. Updating of my logbook and reflective journal for review by my supervisor.
Tuesday
1. Preparation of meeting with supervisor.
Listing down the list of questions and findings to be presented to my supervisor.
Friday
1. Studied through the thesis titled Effect of change of spur gear tooth parameters on bending
and contact stresses
Shot peening is used to increase the tooth bending strength and surface durability in gears.
The surface roughness generated during shot peening leads to macro and micropitting is
now considered the dominant restriction on gear life and performance
It was observed that the maximum bending stress and contact stress decreases with in-
creasing face width, number of teeth and root fillet radius relative to spur gear set weight.
it is recommendable to use optimal values of tooth parameters during design work to reduce
stresses.
Stress reduction results in better tooth root load capacity, micropitting resistance, prolongs
gear service life
Page 32
5 Week 5
Tuesday
1. Updating my Logbook and for subsequent review by my supervisor
2. Preparation of meeting with my supervisor
Prepared a list of findings and questions to be presented to my supervisor.

Preparation of a draft flow chart of my methodology for joint discussion with my supervisor.
Read online through Google search on materials relevant to developing methodology of spur
gear contact stress research.
Wednesday
1. Meeting with supervisor
Discussed with my supervisor on my proposed research methodology.

Supervisor suggests in carrying out the research in various stages i.e. First by developing a
computational model for effect of contact ratio on contact stress and then a computational
model for fatigue life estimation for variable contact ratio gear pairs.
Thursday
1. Studied and tried to evaluate the journal Effect of root radii on stress analysis of involute spur
gear under static loading
From this paper I learnt that the von-mises stresses and the deformation of the gears are
very much dependant on the root radius of the teeth.
The total deformation as well as von-mises stresses of the tooth directly dicreases as the
root radius increases.
Page 33
6 Week 6
Monday
1. Read through the material Stress analysis of spur gear drive using finite element method by
varying pressure angle and understood
teeth with higher pressure angle have better performance than common pressure angles of
14.5, 20 degree for shear stress minimization.
The load capacity of the gear drive is increased by the pressure angle decreasing value.
Tuesday
1. Preparation for meeting with supervisor
Writing down various findings, questions and preparing amendments made for my method-
ology.
Wednesday
1. Meeting day with supervisor
Presentation of progress and current findings

Discussion regarding research paper assessment
Discussion on recommended upcoming activity
2. Read through the paper Effect of pressure angle of spur gears on bending and contact stresses:
a comparative study using finite element software and understood that
With an increase in pressure angle (i.e from 14.5 to 30 degrees), there is a decrease in
bending stress.
With an increase in pressure angle (i.e from 14.5 to 30 degrees), there is a decrease in
contact stress.
Friday
1. Continued works on the preparing the research paper for submission in week 10.
2. Preparation weekly outputs and outcomes schedule for the research paper.
Page 34
7 Week 7
Monday
1. Completed work on the aims and objectives of my project
2. Refining the current progress of my literature review
Tuesday
1. Refining of research paper in preparation for submission in week 10.
2. Meeting with another senior currently taking FYRP2 for further discussion on the project.
3. Preparation of for the meeting with the supervisor.
Noting down questions and further confirmations required by me.

Read through again some of the past identified literature related to contact ratio contact
stress analyses.
Wednesday
1. Meeting with the supervisor
Discussed with him about newly acquired literature materials.
Friday
1. Read through the paper 3D contact stress analysis for spur gears and understood that
The stress distribution in the front plane for 3D model proves the same shape as the 2D
model stress distribution, but the values are smaller with 10%-15%.
The stress distribution along the face width proves to have the same shape as the load
distribution but NOT the same shape as the tooth edge deformations.
The stress increase significantly due to triangular load distribution, that means under non-
uniform contact conditions in the meshing process.
Page 35
8 Week 8
Monday
1. Updated my logbook on my current progress
2. Worked on improving the content of reflective journal 2 due to submitted next week.
Tuesday
1. Preparation for the meeting with the supervisor
Documented the questions I need to ask him.

Discussed with another research student, who is conducting different research and shared
ideas with him regarding model setups.
Wednesday
1. Studied through the paper Frictional contact stress analysis of spur gear by using Finite Element
Method and understood that
The contact stress increased with the increase of friction coefficient.

The contact stress decreased with the increase of face width, showing an inversely propor-
tional relation between them.
Page 36
9 Week 9
Monday
1. Updated my logbook on my current progress.
Tuesday
1. Preparation of meeting with supervisor.
Noting down questions and further confirmations required by me.

Read through again some of the past identified literature.
Wednesday
1. Meeting with my supervisor.
Friday
1. Read through the journal paper Parametric stress analysis of spur gear tooth and understood
that
Contact stress decreases linearly as pressure angle increases.

Contact stress decreases linearly as face width increases.
On increasing transmission ratio corresponding pressure angle contact stress decreases.
But this difference is of very small magnitude in comparison with the actual stress values
and can be attributed to the difference in the theories involved.
To increase load carrying capacity of tooth pressure angle such be increased.
A shorter gear tooth will produce more concentrated areas of stress which is ideally avoided,
and should only be done if space is a major constraint.
Page 37
10 Week 10
Monday
1. Prepared and updated my logbook
2. Developing the subtopics and layout for the final report.
3. Commenced writing of the final report.
4. Commenced working on Introduction of my final report.
Tuesday
1. Preparing for the meeting with Supervisor.
Preparing the final report which included the compilation of the literature review, intro-
duction and current results and appendices.
Updating the contents of my literature review.
Wednesday
Presented the progress made on my final report
Thursday
1. Read through the journal Frictional tooth contact analysis along line of action of a spur gear
using Finite element method and understood that
FE model results have a high degree of coincidence with the theoretical results.
The contact stress calculated for different coefficient of friction showed that the contact
stresses increased with the increasing value of static coefficient of friction. A 10% rise has
been observed when the friction coefficient value was increased from 0 to 0.3.
The increase in the contact stresses with the increase in friction coefficient provides with
an idea of friction factor to be incorporated while calculating the contact stress in meshed
gears.
Page 38
Friday
1. Read through the journal Non-Linear Contact Analysis of Meshing Gears and understood that
The contact between pinion and gear is highly non-linear because the surfaces of the tooth
could come into and out of contact in a sudden manner.
Fine tuning is required for the FEA model especially at the single tooth contact zone.
One of the ideal forms of comparison would be utilizing experimental testing.
Experimental activities are expensive and lengthy.
Page 39
11 Week 11
Monday
1. Updating and preparing workbook and reflective journal for submission.
2. Emailed my supervisor the completed simulation results.
Tuesday
1. Analyzing my results and commenced the discussions.
2. Prepared a compiled draft final report of all the progress made so far for presentation to my
supervisor tomorrow.
Wednesday
1. Meeting with supervisor.
Reported my findings regarding my discussion to the supervisor.

Discussed with the supervisor the format of making my discussions.
Discussed with him on how to properly write my abstract and introduction.
Discuss with him further about the overall expectations of the final report.
2. Continued work on the final report.
Thursday
1. Read through the journal Experimental stress analysis spur gear using ansys software and
understood that
The parametric model is capable of creating spur gears with different modules and number
of teeth by modifying the parameters and regenerating the model.
It is possible to carry out finite element analysis such as root bending stress and contact
stresses between gear teeth pair and effect of root fillet radius on the root stresses.
Simulation results have good agreement with the theoretical results.
2. Continued work on the final report and sent the current state to the supervisor.
Page 40
12 Week 12
Monday
1. Updated and prepared the logbook and reflective journal for submission.
2. Continued final work on finalizing the work on the final report.
Tuesday
1. Preparation for the meeting with supervisor.
Completed and formatted the final report for discussion with the supervisor the next day
for a final review before submission.
Listing down question to ask the supervisor before final submission of the report.
2. Continued work on improving the final report
Wednesday
Presented to him my own outline for the oral presentation.

Discussed on the presentation slides for the presentation
Advised me on how to conduct my upcoming presentation.
Asked for any necessary work to be done before submission of the final report.
2. Working and preparing draft of my presentation slides.
Thursday
1. Reviewed holistically the whole final report before my scheduled submission tomorrow.
2. Showed an discussed with a senior Ph.D student my final report and seeking his own comments.
Page 41
Friday
1. Submitted the final report
2. Completed the final presentation slides for the presentation
3. Final review of my Modules, workbook and reflective journal before hard copy submissions.
Page 42
13 Documents
122 BudynasNisbett: Shigleys I. Basics 3. Load and Stress Analysis The McGrawHill
Mechanical Engineering Companies, 2008
Design, Eighth Edition
Load and Stress Analysis 117
319 Contact Stresses

When two bodies having curved surfaces are pressed together, point or line contact
changes to area contact, and the stresses developed in the two bodies are three-
dimensional. Contact-stress problems arise in the contact of a wheel and a rail,
in automotive valve cams and tappets, in mating gear teeth, and in the action of
rolling bearings. Typical failures are seen as cracks, pits, or flaking in the surface
material.
The most general case of contact stress occurs when each contacting body has a
double radius of curvature; that is, when the radius in the plane of rolling is different
from the radius in a perpendicular plane, both planes taken through the axis of the con-
tacting force. Here we shall consider only the two special cases of contacting spheres
and contacting cylinders.14 The results presented here are due to Hertz and so are fre-
quently known as Hertzian stresses.
Spherical Contact
When two solid spheres of diameters d1 and d2 are pressed together with a force
F, a circular area of contact of radius a is obtained. Specifying E 1 , 1 and E 2 , 2
as the respective elastic constants of the two spheres, the radius a is given by the
equation
!
2
E 1 + 1 22 E 2
" #$ " #$
3 3F 1 1 (368)
a=
8 1/d1 + 1/d2
The pressure distribution within the contact area of each sphere is hemispherical, as shown
in Fig. 336b. The maximum pressure occurs at the center of the contact area and is
3F
pmax = (369)
2a 2
Equations (368) and (369) are perfectly general and also apply to the contact of
a sphere and a plane surface or of a sphere and an internal spherical surface. For a plane
surface, use d = . For an internal surface, the diameter is expressed as a negative
quantity.
The maximum stresses occur on the z axis, and these are principal stresses. Their
values are

( ) ) *
) z ) 1 1 1
1 = 2 = x = y = pmax 1 ) a ) tan |z/a| (1 + ) (
) ) *
z2
2 1+ 2
a
(370)
pmax
3 = z = (371)
z2
1+ 2
a
14
A more comprehensive presentation of contact stresses may be found in Arthur P. Boresi and Richard
J. Schmidt, Advanced Mechanics of Materials, 6th ed., Wiley, New York, 2003 pp. 589623.
Page 43
BudynasNisbett: Shigleys I. Basics 3. Load and Stress Analysis The McGrawHill 123
118 Mechanical Engineering Design
Figure 336 F F
(a) Two spheres held in

x
contact by force F; (b) contact
stress has a hemispherical
distribution across contact d1
zone diameter 2a.
y y
2a
d2
F F
z z
(a) (b)
These equations are valid for either sphere, but the value used for Poissons ratio
must correspond with the sphere under consideration. The equations are even more com-
plicated when stress states off the z axis are to be determined, because here the x and y
coordinates must also be included. But these are not required for design purposes,
because the maxima occur on the z axis.
Mohrs circles for the stress state described by Eqs. (370) and (371) are a point
and two coincident circles. Since 1 = 2 , we have 1/2 = 0 and
1 3 2 3
max = 1/3 = 2/3 = = (372)
2 2
Figure 337 is a plot of Eqs. (370), (371), and (372) for a distance to 3a below the
surface. Note that the shear stress reaches a maximum value slightly below the surface.
It is the opinion of many authorities that this maximum shear stress is responsible for
the surface fatigue failure of contacting elements. The explanation is that a crack orig-
inates at the point of maximum shear stress below the surface and progresses to the sur-
face and that the pressure of the lubricant wedges the chip loose.
Cylindrical Contact
Figure 338 illustrates a similar situation in which the contacting elements are two
cylinders of length l and diameters d1 and d2 . As shown in Fig. 338b, the area of con-
tact is a narrow rectangle of width 2b and length l, and the pressure distribution is
elliptical. The half-width b is given by the equation
!
2F 1 12 E 1 + 1 22 E 2
" #$ " #$
(373)
b=
l 1/d1 + 1/d2
Page 44
124 BudynasNisbett: Shigleys I. Basics 3. Load and Stress Analysis The McGrawHill
Load and Stress Analysis 119
!, "
Figure 337
Magnitude of the stress 1.0
components below the surface
as a function of the maximum
pressure of contacting spheres. 0.8
Note that the maximum shear
!z
!Ratio of stress to pmax!
stress is slightly below the

surface at z = 0.48a and is 0.6
approximately 0.3pmax. The !x , !y
chart is based on a Poisson
ratio of 0.30. Note that the 0.4
normal stresses are all
"max
compressive stresses.
0.2
0 z
0 0.5a a 1.5a 2a 2.5a 3a
Distance from contact surface
Figure 338 F
F
(a) Two right circular cylinders x

held in contact by forces F x
uniformly distributed along
cylinder length l. (b) Contact d1
stress has an elliptical
distribution across the l
contact zone width 2b. y y
2b
d2
F
F
z z
(a) (b)
The maximum pressure is

2F
pmax = (374)
bl
Equations (373) and (374) apply to a cylinder and a plane surface, such as a rail, by
making d = for the plane surface. The equations also apply to the contact of a cylin-
der and an internal cylindrical surface; in this case d is made negative for the internal
surface.
Page 45
BudynasNisbett: Shigleys I. Basics 3. Load and Stress Analysis The McGrawHill 125
120 Mechanical Engineering Design
The stress state along the z axis is given by the equations

./ ) )0
z 2 )) z ))
x = 2pmax 1+ 2 ) ) (375)
b b
z2

1 + 2 b2
) )
) z )
y = pmax
/ 2)) )) (376)
z 2 b
1+ 2
b
pmax
3 = z = 7 (377)
1 + z 2 /b2
These three equations are plotted in Fig. 339 up to a distance of 3b below the surface.
For 0 z 0.436b, 1 = x , and max = (1 3 )/2 = (x z )/2. For z 0.436b,
1 = y , and max = ( y z )/2. A plot of max is also included in Fig. 339, where the
greatest value occurs at z/b = 0.786 with a value of 0.300 pmax .
Hertz (1881) provided the preceding mathematical models of the stress field when
the contact zone is free of shear stress. Another important contact stress case is line of
contact with friction providing the shearing stress on the contact zone. Such shearing
stresses are small with cams and rollers, but in cams with flatfaced followers, wheel-rail
contact, and gear teeth, the stresses are elevated above the Hertzian field. Investigations
of the effect on the stress field due to normal and shear stresses in the contact zone were
begun theoretically by Lundberg (1939), and continued by Mindlin (1949), Smith-Liu
(1949), and Poritsky (1949) independently. For further detail, see the reference cited in
Footnote 14.
!, "
Figure 339
Magnitude of the stress 1.0
components below the surface
as a function of the maximum
pressure for contacting 0.8
cylinders. The largest value of !y
!Ratio of stress to pmax!
!z
max occurs at z/b = 0.786.
Its maximum value is 0.6
0.30pmax. The chart is based
on a Poisson ratio of 0.30.
Note that all normal stresses 0.4
!x
are compressive stresses. "max
0.2
0 z
0 0.5b b 1.5b 2b 2.5b 3b
Distance from contact surface
Page 46
c15.qxd 8/3/11 9:34 PM Page 638
638 Chapter 15 Spur Gears
The next three sections deal with bending fatigue at the base of the tooth and involve
the principles of fatigue analysis covered in Chapter 8. The following two sections are
concerned with surface durability and make use of the information on pitting and scor-
ing given in Chapter 9. Some of the principles of lubrication covered in Chapter 13 are
involved as well. As will be seen, the load capacity and failure mode of a pair of gears
are affected by their rotating speed. Altogether, the study of gear load capacity affords an
excellent opportunity to apply much of the basic material covered in earlier chapters.
15.6 Basic Analysis of Gear-Tooth-Bending Stress (Lewis Equation)

The first recognized analysis of gear-tooth stresses was presented to the Philadelphia
Engineers Club in 1892 by Wilfred Lewis. It still serves as the basis for gear-tooth-
bending stress analysis. Figure 15.20 shows a gear tooth loaded as a cantilever beam,
with resultant force F applied to the tip. Mr. Lewis made the following simplifying
assumptions.
1. The full load is applied to the tip of a single tooth. This is obviously the most
severe condition and is appropriate for gears of ordinary accuracy. For high-
precision gears, however, the full load is never applied to a single tooth tip. With
a contact ratio necessarily greater than unity, each new pair of teeth comes into
contact while the previous pair is still engaged. After the contact point moves
down some distance from the tip, the previous teeth go out of engagement and
the new pair carries the full load (unless, of course, the contact ratio is greater
than 2). This is the situation depicted in Figure 15.19. Thus, with precision
gears (not available in Mr. Lewiss time), the tooth should be regarded as car-
rying only part of the load at its tip, and the full load at a point on the tooth face
where the bending moment arm is shorter.
2. The radial component, Fr , is negligible. This is a conservative assumption, as Fr
produces a compressive stress that subtracts from the bending tension at point a
Fr F
Ft
h
b
rf
a
Constant-
x
strengh
parabola
t
FIGURE 15.20
Bending stresses in a spur gear tooth (comparison with a
constant-stress parabola).
c15.qxd 8/3/11 9:34 PM Page 639
15.6 Basic Analysis of Gear-Tooth-Bending Stress (Lewis Equation) 639
of Figure 15.20. (The fact that it adds to the bending compression in the opposite
fillet is unimportant because fatigue failures always start on the tensile side.)
3. The load is distributed uniformly across the full face width. This is a noncon-
servative assumption and can be instrumental in gear failures involving wide
teeth and misaligned or deflecting shafts.
4. Forces which are due to tooth sliding friction are negligible.
5. Stress concentration in the tooth fillet is negligible. Stress concentration factors
were unknown in Mr. Lewiss time but are now known to be important. This will
be taken into account later.
Proceeding with the development of the Lewis equation, we note from

Figure 15.20 that the gear tooth is everywhere stronger than the inscribed constant-
strength parabola (recall Figure 12.23c), except for the section at a where the
parabola and tooth profile are tangent. At point a
Mc 6Ft h
s = = (c)
I bt 2
by similar triangles,
t/2 h t2
= , or = 4x (d)
x t/2 h
Substituting Eq. d into Eq. c gives
6Ft
s = (e)
4bx
Defining the Lewis form factor y as
y = 2x/3p (f)
and substituting it into Eq. e gives
Ft
s = (15.15)
bpy
which is the basic Lewis equation in terms of circular pitch.

Because gears are more often made to standard values of diametral pitch, we
substitute
p = p/P (15.5, mod)
y = Y/p (g)
into Eq. 15.14 and obtain an alternative form of the Lewis equation:
Ft P
s = (15.16)
bY
c15.qxd 8/3/11 9:34 PM Page 640
640 Chapter 15 Spur Gears
0.60
0.55
25
"=
th
tee
0.50 s tub
,
20
"=
0.45

20
Lewis form factor Y
"=
0.40
1
0.35 14 2
"=
0.30
0.25
0.20
0.15
12 15 17 20 24 30 35 40 4550 60 80 125 275 !
Number of teeth N (Rack)
FIGURE 15.21
Values of Lewis form factor Y for standard spur gears (load applied at tip of the tooth).
Or, when using SI units, we have
Ft
s = (15.16a)
mbY
where Y is the Lewis form factor based on diametral pitch or module. Both Y and y
are functions of tooth shape (but not size) and therefore vary with the number of
teeth in the gear. Values of Y for standard gear systems are given in Figure 15.21. For
nonstandard gears, the factor can be obtained by graphical layout of the tooth or by
digital computation.
Note that the Lewis equation indicates that tooth-bending stresses vary (1)
directly with load Ft , (2) inversely with tooth width b, (3) inversely with tooth size
p, 1/P, or m and (4) inversely with tooth shape factor Y or y.
15.7 Refined Analysis of Gear-Tooth-Bending Strength: Basic Concepts

In addition to the four basic factors included in the Lewis equation, modern gear
design procedures take into account several additional factors that influence gear-
tooth-bending stresses.
1. Pitch line velocity. The greater the linear velocity of the gear teeth (as measured
at the pitch circles), the greater the impact of successive teeth as they come into
contact. These impacts happen because the tooth profiles can never be made with
absolute perfection; and even if they were, deflections are inevitable, for operat-
ing loads cause a slight impact as each new pair of teeth come into engagement.
368 Chapter 9
of specific gear geometry, the results are labor-intensive in terms of setting up the model, and
uncertainty often remains concerning the validity of boundary conditions and material
properties. An alternative to finite element analysis is the use of procedural approaches such
as those outlined in standards developed by the American Gear Manufacturers Association
(AGMA), the British Standards Institution (BSI), and the International Organization for
Standardization (ISO).
This chapter concentrates on analyzing whether failure due to bending and contact
stresses in a gear set is likely. In Section 9.2 a relatively simple relationship for contact
stresses is outlined prior to the introduction of the current AGMA equations for bending
and contact stresses in Section 9.3. The AGMA equations rely on the evaluation of a
significant number of factors and geometrical parameters, which depend on the specific
geometry and materials concerned. In this chapter, the basic approach is outlined for 20!
pressure angle, full depth teeth spur and helical gears only. Many of the detailed charts
and equations given in the source standards have been omitted and the reader is
encouraged to view the most recent standards as necessary. A general strategy for gear
design is outlined in Section 9.4.
9.2 Wear Failure

In addition to failure due to bending stresses in gears, failure due to wear on the
surface of gear teeth should also be considered. Possible surface failures include pitting,
which is a surface fatigue failure due to many repetitions of high contact stresses,
scoring due to failure of lubrication, and abrasion due to the presence of foreign
particles.
The surface compressive, Hertzian, or contact stress for a gear can be modeled by
! " #$
Kv0 Wt 1 1 0:5
sc #Cp (9.1)
F cos f r1 r2
where
Cp is an elastic coefficient,
r1 and r2 are radii of curvature,
Kv0 is the velocity factor,
Wt is the transmitted load (N),
F is the face width (m)
f is the pressure angle (! ).
p
If the units of Cp are in MPa, Wt is in N, and r1,r2 are in meters, then Eqn (9.1) gives the
contact stress sc in kPa.
Spur and Helical Gear Stressing 369
The radii of curvature are given by

dP sin f
r1 (9.2)
2
dG sin f
r2 (9.3)
2
where dP and dG are the pitch diameters of the pinion and gear, respectively.
The velocity factor Kv0 for cut or milled profile gears is given by
6:1 V
Kv0 (9.4)
6:1
where V is the pitch line velocity (m/s).
Note that this definition for the velocity factor, now used in the latest AGMA standards, is the
reciprocal of that previously defined. For this reason, following the notation suggested by
Mischke in Shigley and Mischke (2001), a superscript prime has been added to distinguish it
from previous definitions.
The elastic coefficient Cp can be calculated from Eqn (9.5) or obtained from Table 9.1.
2 30:5
6 1 7
Cp 6 7
4 &1 # n2 1 # n2 '5 (9.5)
P G
p
EP EG
where
vP is Poissons ratio for the pinion,

vG is Poissons ratio for the gear,
EP is Youngs modulus for the pinion,
EG is Youngs modulus for the gear.
p
Table 9.1: Values of the elastic coefficient (Cp ; Ze MPa).
Gear material
Epinion Malleable Nodular Cast Aluminum Tin
Pinion material (GPa) Steel iron iron iron bronze bronze
Steel 200 191 181 179 174 162 158
Malleable iron 170 181 174 172 168 158 154
Nodular iron 170 179 172 170 166 156 152
Cast iron 150 174 168 166 163 154 149
Aluminum bronze 120 162 158 156 154 145 141
Tin bronze 110 158 154 152 149 141 137
Source: AGMA 218.01
370 Chapter 9
Example 9.1
A speed reducer has a 22-tooth spur pinion made of steel, driving a 60-tooth gear made of cast
iron. The transmitted power is 10 kW. The pinion speed is 1200 rpm, module 4, and face
width 50 mm. Determine the contact stress.
Solution
NP 22; steel pinion, NG 60; cast iron gear. n 1200 rpm, m 4, F 50 mm, H 10 kW.
dP mNP 4 % 22 88 mm; dG 4 % 60 240 mm:

0:088 2p
V % 1200 % 5:529 m=s:
2 60
6:1 5:529
Kv0 1:906:
6:1
10;000
Wt 1809 N:
5:529
p
From Table 9.1 for a steel pinion and cast iron gear, Cp 174 MPa:
From Eqns 9.2 and 9.3,
88 % 10#3 sin 20 240 % 10#3 sin 20
r1 0:01505 m; r2 0:04104 m:
2 2
From Eqn (9.1):

! $0:5
1:906 % 1809
sc #174 90:81 #174 % 2581 kPa #449;200 kPa y # 449 MPa:
0:05 cos 20
9.3 AGMA Equations for Bending and Contact Stress

The calculation of bending and contact stresses in spur and helical gears can be determined
using standardized methods presented by the BSI, the ISO, the Deutsches Institut fur
Normung, and the AGMA. The AGMA standards have recently been reaffirmed (ANSI/
AGMA 2101-D04) and are widely used and have therefore been selected for presentation
here. The procedures make extensive use of a series of geometry and design factors, which
can be determined from design charts and tables.
The AGMA formula for bending stress for spur gears is given in SI units by
1 KH KB
s Wt KO KV0 Ks (9.6)
Fm YJ
Ibrahim Khalil Hussaini (4241606)
Page 53
Chapter 2 Sketching Section 2.5 Spur Gears 16
Section 2.5
Spur Gears
Problem Description
To satisfy the fundamental law
of gearing, the gear proles
are cut to an involute curve.
Project Logbook
Page 54
[1] The driving [8] Line of action (common
gear rotates normal of contacting gears).
clockwise. The pressure angle is 20o.
[2] The driven
gear rotates
counter- [4] Pitch circle
clockwise. of the driving
[6] Contact
point (pitch
[3] Pitch circle point).
rp = 2.5 in. [7] Common
[5] Line of tangent of the
centers. pitch circles.
[9] Addendum
ra = 2.75 in.
[12] The llet
has a radius of
0.1 in.
[10]
Dedendum
rd = 2.2 in. [11] The shaft has a
radius of 1.25 in.
Project Logbook
Page 55
Techniques/Concepts
Draw>Construction Point
Draw>Spline
Modify>Replicate
Constraints>Perpendicular
Project Logbook
Page 56
Chapter 3 2D Simulations Section 3.4 Spur Gears 15
Section 3.4
Spur Gears
Problem Description [1] W are
concerned with the
contact stress here.
[2] And the bending
stress here.
Project Logbook
Page 57
Chapter 3 2D Simulations Section 3.4 Spur Gears 16
Techniques/Concepts
Copy bodies (Translate)
Contacts
Frictionless
Symmetric (Contact/Target)
Adjust to Touch
Loads>Moment
True Scale
Project Logbook
14 Videos
Figure 44: Fatigue Analysis in ANSYS Fatigue Failure HCF High Cycle & LCF Low Cycle
Fatigue Life GRS. url: https://www.youtube.com/watch?v=LfOJGkzAJDA
Figure 45: Automatically created parametric gears and springs with Siemens PLM NX 10.0. url:
https://www.youtube.com/watch?v=uaUws7-prcI
Page 58
15 Websites
Finite Element Simulations with ANSYS Workbench 16 by Huei-Huang Lee, NCKU, Taiwan 04/05/2016, 11:47 PM
Books MATLAB2016 ANSYS16 ANSYS15 SWM2015 SWM2014 SWD2015 SWD2014

SWS2015 Taguchi4 TaguchiOpenCourse Dynamics
Finite Element Simulations with ANSYS Workbench 16

by Huei-Huang Lee, NCKU, Taiwan
Amazon.com Search--ANSYS
Amazon.com Search--Finite Element
Google Search--Finite Element Simulations with ANSYS Workbench
Download Lecture Slides
(PDF) Chapter 01. Introduction (Word) Chapter 01

(PDF) Chapter 02. Sketching (Word) Chapter 02
(PDF) Chapter 03. 2D Simulations (Word) Chapter 03
(PDF) Chapter 04. 3D Solid Modeling (Word) Chapter 04
(PDF) Chapter 05. 3D Simulations (Word) Chapter 05
(PDF) Chapter 06. Surface Models (Word) Chapter 06
(PDF) Chapter 07. Line Models (Word) Chapter 07
(PDF) Chapter 08. Optimization (Word) Chapter 08
(PDF) Chapter 09. Meshing (Word) Chapter 09
(PDF) Chapter 10. Buckling and Stress Stiffening (Word) Chapter 10
(PDF) Chapter 11. Modal Analyses (Word) Chapter 11
(PDF) Chapter 12. Transient Structural Simulations (Word) Chapter 12
(PDF) Chapter 13. Nonlinear Simulations (Word) Chapter 13
To order this book, please visit
(PDF) Chapter 14. Nonlinear Materials (Word) Chapter 14
SDC Publications or Amazon.com
(PDF) Chapter 15. Explicit Dynamics (Word) Chapter 15
View Tutorial Videos or Download Finished Project Files

1. The videos have a maximum resolution of 1920x1080 (HD).
2. To reduce file size, the project files were saved with Workbench GUI command /File/Archive...; i.e., they are in WBPZ compressed format. To
open a compressed project file, please use Workbench GUI command /File/Restore Archive...
3. The project files are to be used with ANSYS16 (or later); they are not to be used with ANSYS15 or earlier versions.
4. It is suggested that, whenever a project file is needed to start up an exercise, you use a project file provided here, rather than your own finished
project file, so that your numerical results would be more consistent with those in the textbook.
(Video 05:29) Section 02-1 W16x50 Beam (Finished Project File) Sec 02-1 (Animation) Sec 01-1
(Video 05:16) Section 02-2 Triangular Plate (Finished Project File) Sec 02-2
(Video 05:31) Section 02-4 M20x2.5 Threaded Bolt (Finished Project File) Sec 02-4
(Video 06:46) Section 02-5 Spur Gears (Finished Project File) Sec 02-5
(Video 08:23) Section 02-6 Microgripper (Finished Project File) Sec 02-6
(Video 07:05) Section 03-1 Triangular Plate (Finished Project File) Sec 03-1 (Animation) Sec 03-1
(Video 09:44) Section 03-2 Threaded Bolt-and-Nut (Finished Project File) Sec 03-2 (Animation) Sec 03-2
(Video 05:45) Section 03-4 Spur Gears (Finished Project File) Sec 03-4 (Animation) Sec 03-4
(Video 11:59) Section 03-5 Filleted Bar (Finished Project File) Sec 03-5 (Animation) Sec 03-5
(Video 03:50) Section 04-1 Beam Bracket (Finished Project File) Sec 04-1
(Video 12:15) Section 04-2 Cover of Pressure Cylinder (Finished Project File) Sec 04-2
http://myweb.ncku.edu.tw/~hhlee/Myweb_at_NCKU/ANSYS16.html Page 1 of 2
Page 59
Finite Element Simulations with ANSYS Workbench 16 by Huei-Huang Lee, NCKU, Taiwan 04/05/2016, 11:47 PM
(Video 06:39) Section 04-3 Lifting Fork (Finished Project File) Sec 04-3
(Video 06:33) Section 04-5 LCD Display Support (Finished Project File) Sec 04-5
(Finished Project File) Sec 04-6-2
(Video 04:12) Section 05-1 Beam Bracket (Finished Project File) Sec 05-1 (Animation) Sec 05-1
(Video 04:23) Section 05-2 Cover of Pressure Cylinder (Finished Project File) Sec 05-2 (Animation) Sec 05-2
(Video 03:20) Section 05-4 LCD Display Support (Finished Project File) Sec 05-4 (Animation) Sec 05-4
(Video 07:50) Section 06-1 Bellows Joints (Finished Project File) Sec 06-1 (Animation) Sec 06-1
(Video 11:37) Section 06-3 Gearbox (Finished Project File) Sec 06-3 (Animation) Sec 06-3
(Video 08:00) Section 07-1 Flexible Gripper (Finished Project File) Sec 07-1 (Animation) Sec 07-1
(Video 11:56) Section 07-2 3D Truss (Finished Project File) Sec 07-2 (Animation) Sec 07-2
(Video 13:18) Section 07-3 Two-Story Building (Finished Project File) Sec 07-3 (Animation) Sec 07-3
(Video 07:51) Section 08-1 Flexible Gripper (Finished Project File) Sec 08-1 (Animation) Sec 08-1
(Video 05:51) Section 08-2 Triangular Plate (Finished Project File) Sec 08-2 (Animation) Sec 08-2
(Video 11:59) Section 09-1 Pneumatic Fingers (Finished Project File) Sec 09-1 (Animation) Sec 09-1
(Video 05:25) Section 09-2 Cover of Pressure Cylinder (Finished Project File) Sec 09-2
(Video 11:37) Section 09-3 Convergence of 3D Elements (Finished Project File) Sec 09-3 (Animation) Sec 09-3
(Video 07:58) Section 10-1 Stress Stiffening (Finished Project File) Sec 10-1 (Animation) Sec 10-1
(Video 02:19) Section 10-2 3D Truss (Finished Project File) Sec 10-2 (Animation) Sec 10-2
(Video 02:19) Section 11-1 Gearbox (Finished Project File) Sec 11-1 (Animation) Sec 11-1
(Video 04:18) Section 11-2 Two-Story Building (Finished Project File) Sec 11-2 (Animation) Sec 11-2
(Video 05:45) Section 11-3 Compact Disk (Finished Project File) Sec 11-3 (Animation) Sec 11-3
(Video 03:59) Section 11-4 Guitar String (Finished Project File) Sec 11-4 (Animation) Sec 11-4
(Video 07:24) Section 12-2 Lift Fork (Finished Project File) Sec 12-2 (Animation) Sec 12-2
(Video 04:03) Section 12-3 Two-Story Building (Finished Project File) Sec 12-3
(Video 08:37) Section 12-4 Disk and Block (Finished Project File) Sec 12-4 (Animation) Sec 12-4
(Video 05:35) Section 12-5 Guitar String (Finished Project File) Sec 12-5 (Animation) Sec 12-5
(Video 09:47) Section 13-2 Translational Joint (Finished Project File) Sec 13-2 (Animation) Sec 13-2
(Video 11:33) Section 13-3 Microgripper (Finished Project File) Sec 13-3 (Animation) Sec 13-3
(Video 14:18) Section 13-4 Snap Lock (Finished Project File) Sec 13-4 (Animation) Sec 13-4
(Video 11:36) Section 14-2 Belleville Washer (Finished Project File) Sec 14-2 (Animation) Sec 14-2
(Video 14:17) Section 14-3 Planar Seal (Finished Project File) Sec 14-3 (Animation) Sec 14-3
(Testdata.xls) Test Data Sec 14-3
(Video 05:43) Section 15-2 High-Speed Impact (Finished Project File) Sec 15-2 (Animation) Sec 15-2
(Video 08:05) Section 15-3 Drop Test (Finished Project File) Sec 15-3 (Animation) Sec 15-3
http://myweb.ncku.edu.tw/~hhlee/Myweb_at_NCKU/ANSYS16.html Page 2 of 2
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Swinburne University of Technology (Sarawak

Faculty of Engineering, Computing and Science

November 18, 2016

Figure 1: Geometry of Model A.

Figure 2: Model A meshed.

Figure 3: Equivalent von-Mises (Kf=1.0)

Figure 4: Equivalent von-Mises (Kf=0.9)

Figure 5: Equivalent von-Mises (Kf=0.8)

Figure 6: Equivalent von-Mises (Kf=0.7)

Figure 7: Max shear (Kf=1.0)

Figure 8: Max shear (Kf=0.9)

Figure 9: Max shear (Kf=0.8)

Figure 10: Max shear (Kf=0.7)

Figure 11: Geometry of Model B

Figure 12: Contact settings for Model B

Figure 13: Model B meshed

Figure 14: Model B boundary conditions

Figure 15: Model B equivalent von-Mises stress

Figure 16: Model B safety factor

Figure 17: Equivalent von-Mises (Kf=1.0)

Figure 18: Equivalent von-Mises (Kf=0.9)

Figure 19: Equivalent von-Mises (Kf=0.8)

Figure 20: Equivalent von-Mises (Kf=0.7)

Figure 21: Max shear (Kf=1.0)

Figure 22: Max shear (Kf=0.9)

Figure 23: Max shear (Kf=0.8)

Figure 24: Max shear (Kf=0.7)

Figure 25: Equivalent von-Mises stress ( = 0)

Figure 26: Equivalent von-Mises stress ( = 0.01)

Figure 27: Equivalent von-Mises stress ( = 0.05)

Figure 28: Equivalent von-Mises stress ( = 0.1)

Figure 29: Equivalent von-Mises stress ( = 0.15)

Figure 30: Equivalent von-Mises stress ( = 0.2)

Figure 31: Geometry of Model C

Figure 32: Contact conditions of Model C

Figure 33: Mesh of Model C

Figure 34: Boundary conditions of Model C

Figure 35: Model C Equivalent von-Mises stress

Figure 36: Equivalent von-Mises (Kf=1.0)

Figure 37: Equivalent von-Mises (Kf=0.9)

Figure 38: Equivalent von-Mises (Kf=0.8)

Figure 39: Equivalent von-Mises (Kf=0.7)

Figure 40: Max shear (Kf=1.0)

Figure 41: Max shear (Kf=0.9)

Figure 42: Max shear (Kf=0.8)

Figure 43: Max shear (Kf=0.7)

Supervisor Name Date & Signature

2. Researched about the parameter to be analyzed which is contact ratio.

Instructed to conduct research on contact stress computational models.

Supervisor Name Date & Signature

Supervisor Name Date & Signature

Listing down the list of questions and findings to be presented to my supervisor.

Supervisor Name Date & Signature

2. Preparation of meeting with my supervisor

Prepared a list of findings and questions to be presented to my supervisor.

Discussed with my supervisor on my proposed research methodology.

Supervisor Name Date & Signature

Presentation of progress and current findings

Supervisor Name Date & Signature

2. Refining the current progress of my literature review

3. Preparation of for the meeting with the supervisor.

Noting down questions and further confirmations required by me.

Discussed with him about newly acquired literature materials.

Supervisor Name Date & Signature