Chapter 1

Introduction

Gears are highly engineered machine elements that must be designed not only to meet the torque,
speed, life and noise requirements under nominal conditions, but also to compensate for adverse
effects due to manufacturing errors, variations and elastic deformations of the support structures. In
addition to the elastic deformation of the support and structures, manufacturing errors in the gears,
shafts and housing must also be considered in the design. Assuming that perfectly aligned shafts
support a gear pair in which the shafts, bearings and the housing are all rigid might lead to severe
wear and noise problems.

A reasonably accurate gear pair, with a limited amount of tooth surface manufacturing errors
and operated under ideal (no error and no deflection) support conditions, can be expected to exhibit a
good load distribution along its face width. If the shafts are mounted on bearings with position errors,
or the shafts, bearings and housing deflect under load, and then the rotational axes of the gears will no
longer be parallel to each other. These conditions cause a mismatch of meshing teeth, resulting in a
non-uniform load distribution along the face width, with perhaps very little or no load on one side and
a larger edge load on the other. Such poor load distribution conditions might result in contact and
tooth bending stresses at the overloaded side that are higher than the allowable (designed) limits, thus
triggering premature bending or contact fatigue failures. Such poor load distribution also accelerates
the rate of wear at the gear tooth surfaces.

The common problem in the rotating mechanisms is shaft misalignments. Misalignment in the
meshing gear results in uneven load distribution resulting in shift of peak bending stress to the edge of
face width. Misalignment in meshing alters the location of contact on tooth flank and may lead to
large stresses and increase noise of gear pair.

When we have problems with gear set failure, a common diagnosis is misalignment. What
exactly is that and how do we prevent it? The second most common "killer" of good gear sets
is misalignment (dirt, or abrasive wear, is first). Gear teeth simply won't carry the load if they don't
touch, and the portion that does touch has to carry an overload to make up for the missing contact
area. Gear mesh misalignment may result in shifts in the load distribution of a gear pair that results in
increasing contact and bending stresses, moving the peak bending stresses to the edge of the face
width, and might also increase gear noise.

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2.2 What are Power Transmitting (Gears) Elements?
2.2.1 DEFINITION OF GEARS

Gears are toothed members which transmit power / motion between two shafts by
meshing without any slip. Hence, gear drives are also called positive drives. In any pair of gears,
the smaller one is called pinion and the larger one is called gear immaterial of which is driving
the other. When pinion is the driver, it results in step down drive in which the output speed
decreases and the torque increases. On the other hand, when the gear is the driver, it results in
step up drive in which the output speed increases and the torque decreases.

2.2.2 SPUR GEAR

Spur gears have their teeth parallel to the axis Fig.2.1 and are used for transmitting power
between two parallel shafts. They are simple in construction, easy to manufacture and cost less.
They have highest efficiency and excellent precision rating. They are used in high speed and high
load application in all types of trains and a wide range of velocity ratios. Hence, they find wide
applications right from clocks, household gadgets, motor cycles, automobiles, and railways to
aircrafts. One such application is shown in Fig 2. 1

Fig.2.1 Spur Gear Pair

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 Chapter 2

Literature Survey
V. Roda-Casanova [1], when two gears are misaligned, they do not mesh properly and a defective
contact pattern is produced, leading to uneven load distributions along the face width of the gear teeth.
These uneven load distributions may result in bending and contact stresses exceeding the permissible
values that can cause premature fatigue failure. However, the negative consequences of the
misalignment of the gears are not limited to reducing its load carrying capacity. It has been shown that
they also favour the occurrence of other adverse effects, such as an increase of wear in the contact
surfaces, an increase of heat generation and the introduction of transmission errors, vibration and
noise. The main causes that produce the misalignment of gears are the manufacturing and assembly
errors the distortions produced by thermal and centrifugal effects, and the elastic deflections of the
elements of the transmission under load.

The axial displacement of the pinion is practically zero with the simple supported shaft, but it
is not zero with tapered roller bearing as supports because of the axial load induced by the radial load
in the bearings. This displacement increases as the mounting position of the pinion over the shaft gets
away from the midpoint of the bearing span.

The relationship between all parameters of the misalignment (angular misalignment, transversal
displacement and axial displacement) and the transmitted torque is practically linear in both types of
models (with simple supported shaft and with bearing supported shaft) because of the high stiffness of
the elements of the transmission.

The determination of the total transversal displacement of the pinion by computing separately
the displacement produced by the deflection of the roller bearings and the displacement produced by
the deflection of a simply supported shaft and, then, by applying the principle of superposition is a
common practice. The studies demonstrated that, within the scope of this work, this practice implies a
low error because the small deflections of the structural elements reduce the non-linearity of the
coupled structural and contact problem.

Ankur Saxena[2], The mesh stiffness decreases due to misalignment of gear shaft and friction
forces. Effect of friction during approach and recess is visible while calculating the time varying mesh
stiffness (TVMS). These results show that misalignment and friction cannot be neglected while
calculating TVMS of gear pair. The TVMS values obtained from this study can be used in finding
response of gear pair using dynamic modelling.

Vilmos V. Simon[5], The tooth spacing error gradually worsens the load sharing among the
tooth pairs instantaneously engaged, until it eliminates one of the tooth pairs from contact. The

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negative effects of tooth spacing errors cannot be considerably reduced by gear tooth modifications
introduced by the use of an oversized hob. The tooth modifications introduced by an oversized hob
are of no effect in the case of tooth contact pressure and transmission error increase caused by the
angular misalignment of worm shaft in the vertical, middle, plane of the gear, too. The effects of
angular misalignments of worm shaft in the plane passing through the worm axis and parallel to the
gear axis, eh, can be reduced by hob oversize, but only in the case of its positive values; for negative
values of angle eh this type of modifications is not useful. It is the same for worm gear axial offset,
only for its positive values can be reduced the tooth contact pressure and transmission errors by the
use of an oversized hob.

Shuting Li [4], the effect of tooth profile modification, lead relieving and transmitted torque
on tooth contact stresses, load-sharing ratio and mesh stiffness of a pair of spur gears is investigated in
this paper. The effect of misalignment errors of the gear shafts on the plane of action and lead
crowning on tooth mesh stiffness is also investigated It is found that the tooth profile modification has
significant effects on tooth load-sharing ratio and mesh stiffness. The contact of two pairs of contact
teeth at the double pair tooth engagement positions can become the contact of one pair of contact teeth
when the tooth profile modification is great.

Sheng Li [3] The impacts of the angular misalignment that is tangent to the plane of
action on the contact fatigue life of micro pitting crack nucleation are examined, considering
an example spur gear pair. The computational approach involves the solution of the
governing equations of the spur gear mixed EHL for the determination of the surface traction
distributions, the evaluation of the near-surface cyclic stress concentrations using a boundary
element based near-surface stress model, and the fatigue damage assessment using a multi-
axial fatigue criterion. The lead direction circular crown is demonstrated to be an effective
method for the alleviation of the misalignment-caused heavy tooth surface load and thus
extends the fatigue life. It is shown the optimized crown magnitude for fatigue life
improvement exists, and it is dependent on both the misalignment amount and the input
torque of the gear pair.
Yi Guoa,[4]2015, Theoretical and experimental study on gear-coupling contact and loads
considering misalignment, torque, and friction influences In which the A new analytic model
addresses the tooth contact and induced loads of gear couplings that are affected by misalignment,
torque, and friction. The contact model accounts for Hertzian, bending, and shear deformations of
coupling teeth considering crown modifications. For a specified torque and shaft misalignment, the
model calculates the number of teeth in contact, tooth load, stiffness, stress, deformation, and safety
factors. The tooth load distribution around the circumference compares well with high fidelity finite-
element/contact-mechanics analyses. Simulation time with the analytic model is orders of magnitude

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less. Using the local contact characteristics, the model computes coupling loads that are primarily
caused by the disrupted tooth contact and sliding friction caused by axial motions. This analytic
model was validated by experiments. The load amplitude depends on the misalignment, torque, and
friction. At low torque, coupling motion was induced by the eccentricity between the hub and sleeve
even with nearly perfect alignment. This eccentricity was caused by its self-weight. When torque was
larger than a threshold, the motion amplitude was greatly reduced. This torque threshold

Sian yu [5] 2015 High-contact-ratio spur gears with or without flank modification Considering tip
corner contact and shaft misalignment considering tip corner contact and shaft misalignment High-
contact-ratio (HCR) spur gears have the advantages of reducing the acting loads on the teeth, well as
noise and vibration. However, the phenomenon of tip corner contact and the influence of shaft
misalignments can cause unexpected damage and vibration. Flank modification is a solution for these
influences. An efficient computerized tool for loaded tooth contact analysis (LTCA) is proposed in
this paper that can be used to design HCR gears, while taking into consideration the conditions of tip
corner contact and shaft misalignment. The LTCA method is developed based on the influence
coefficient method and considers both the deformation of the loaded teeth and the twist deformation
of the shaft. The variations of the shared loads and contact stress of a HCR spur gear pair with lead
crowning and relieved profiles are analysed considering the influence of the amount of shaft
misalignment and relief. The contact patterns as well as the stress distribution.

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 Chapter 4

Modelling of gear
Modelling of gear is done in the solid works the parameters for gear are as follows

Parameter Value Unit

Module 6 mm
Pressure Angle 20 Degree
No. teeth on pinion 20
No teeth on gear 40
Pitch Diameter of pinion 120 mm
Pitch Diameter of Gear 240 mm
Centre Distant 180 mm
Moment 2000000 Nmm
Shaft hole diameter 60 mm
Pinion
Shaft hole diameter gear 120 mm

4.1 Table. Parameter of gear pair

Fig. Gear geometry with Teeth in contact

The gear is modelled in solid work ,for the simplified gear meshing at contact the rest gear
tooth which ineffective analysis and consume more memory are removed so result are
good.

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 Chapter 5

Boundary conditions
The model developed in solid work is now imported in the ansys for the stress analysis
Diagram are represented in as below

1. Fixed Support to Gear

Fig 5.1 Fixed supports to gear

Fig5.2.Frictionless support to the pinion

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 Fig.5.3 Moment

Fig.5.4 Mesh View of gear

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 Chapter 6

Results and Graph

The von misses and other output result obtain in ansys given below

1) Principal stress

Principal stress for C.D.=180

Principal stress for C.D.=180.2

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 Principal stress for C.D.=180.4

Principal stress for C.D.=180.8

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 Principal stress for C.D.=181

2) Von misses

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3) Contact Stress

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Graphs Results and Discussion

max. principal stress

106
104
Max.Principal Strss

102
100
98
96
94 max. principal stress

92
90
88
179.8 180 180.2 180.4 180.6 180.8 181 181.2

Linear Misalignment

Graph 6.1 Max Principal stress Vs Linear Misalignment

contact stress
280

275

270
Contact stress

265

260 contact stress

255

250

245
179.8 180 180.2 180.4 180.6 180.8 181 181.2

Linear Misalignment

Graph1.2) Contact stress VS Linear misalignment

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 max. von mises
250

200
Max. Von Mises Stress

150

100 max. von mises

50

0
179.8 180 180.2 180.4 180.6 180.8 181 181.2

Linear Misalignment

Graph1.1) Max von misses stress VS Linear misalignment

shear stress
120
118
116
Max.Shear Stress

114
112
110
108
shear stress
106
104
102
100
179.8 180 180.2 180.4 180.6 180.8 181 181.2

Linear misalignment

Graph Max shear stress Vs. Linear Misalignment

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 References
[1] V. Roda-Casanova, F. Sanchez-Marin, Contribution of the deflection of tapered
roller bearings to the misalignment of the pinion in pinion-rack transmission.
Mechanism and Machine Theory 109 (2017) 7894.
[2] Ankur Saxena, Anand Parey, Manoj Chouksey, Effect of shaft misalignment and
friction force on time varying mesh stiffness of spur gear pair. Engineering
Failure Analysis 49 (2015) 7991.
[3] Sheng Li, An Investigation on the Influence of Misalignment on Micro pitting of a
Spur Gear Pair. Tribol Lett (2015) 60:35.
[4] Shuting Li, Effects of misalignment error, tooth modifications and transmitted
torque on tooth engagements of a pair of spur gears. Mechanism and Machine
Theory 83 (2015) 125136
[5] Vilmos V. Simon, Influence of tooth errors and shaft misalignments on loaded
tooth contact in cylindrical worm gears, Mechanism and Machine Theory 41
(2006) 707724.
[6] M. R. Lias, T.V.V.L.N. Rao, M.Awang and M. A. Khan, The stress distribution of
gear tooth due to axial misalignment condition. Journal of applied sciences
12(23): 2404-2410,2012.
[7] Robert L. Machine Design an integrated approach. Norton.Pearson.
[8] Earle Buckingham, Analytical mechanics of gears. Dover publications, inc.

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