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Spur Gear Tooth Stress Analysis And Stress Reduction

V.Rajaprabakaran1, Mr.R.Ashokraj2
1
Student of M.E.in Mechanical dept., JJ College of Engineering and Technology, Trichy.
2
Assistan Professor in Mechanical dept., JJ College of Engineering and Technology, Trichy.

ABSTRACT: Gears are commonly used for transmitting power. They develop high stress concentration at the
root and the point of contact. The repeated stressing on the fillets causes the fatigue failure of gear tooth. The
main objective of this study is to add different shaped holes to reduce stress concentration. A finite element
model of Spur gear with a segment of three teeth is considered for analysis and stress concentration reducing
holes of various sizes are introduced on gear teeth at various locations. Analysis revealed that aero-fin shaped
hole introduced along the stress flow direction yielded better results.

I. Introduction
Gears are used for a wide range of industrial applications. They have varied application starting from
textile looms to aviation industries. They are the most common means of transmitting power. They change the
rate of rotation of machinery shaft and also the axis of rotation. For high speed machinery, such as an
automobile transmission, they are the optimal medium for low energy loss and high accuracy. Their function is
to convert input provided by prime mover into an output with lower speed and corresponding higher torque.
Toothed gears are used to transmit the power with high velocity ratio. During this phase, they encounter high
stress at the point of contact. A pair of teeth in action is generally subjected to two types of cyclic stresses:
i) Bending stresses inducing bending fatigue
ii) Contact stress causing contact fatigue.
Both these types of stresses may not attain their maximum values at the same point of contact. However,
combined action of both of them is the reason of failure of gear tooth leading to fracture at the root of a tooth
under bending fatigue and surface failure, due to contact fatigue.
When loads are applied to the bodies, their surfaces deform elastically near the point of contact. Stresses
developed by Normal force in a photo-elastic model of gear tooth. The highest stresses exist at regions where
the lines are bunched closest together.
The highest stress occurs at two locations:
1. At contact point where the force F acts
2. At the fillet region near the base of the tooth.
3.
The surface failures occurring mainly due to contact fatigue are pitting and scoring. It is a phenomenon
in which small particles are removed from the surface of the tooth due to the high contact stresses that are
present between mating teeth. Pitting is actually the fatigue failure of the tooth surface. Hardness is the primary
property of the gear tooth that provides resistance to pitting. In other words, pitting is a surface fatigue failure
due to many repetitions of high contact stress, which occurs on gear tooth surfaces when a pair of teeth is
transmitting power. Gear teeth failure due to contact. Fatigue is a common phenomenon observed. Even a slight
reduction in the stress at root results in great increase in the fatigue life of a gear. For many years, gear design
has been improved by using improved material, hardening surfaces with heat treatment and carburization, and
shot peening to improve surface finish etc.

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Few more efforts have been made to improve the durability and strength by altering the pressure angle,
using the asymmetric teeth, altering the geometry of root fillet curve and so on. Some research work is also
done using the stress redistribution techniques by introducing the stress relieving features in the stressed zone to
the advantage of reduction of root fillet stress in spur gear. This also ensures interchange ability of existing gear
systems.
The studies in which combination of circular and elliptical stress relieving features are used obtained better
results than using circular stress relieving features alone which are used by earlier researchers. In this research
work, an aero-fin shaped stress relieving feature is tried. A finite element model with a segment of three teeth is
considered for analysis and a stress relieving feature of various sizes are introduced on gear teeth at various
locations

II. Purpose:
Gearing is one of the most critical components in mechanical power transmission systems. The transfer
of power between gears takes place at the contact between the mating teeth. During operation, meshed gears‟
teeth flanks are submitted to high contact pressures and due to the repeated stresses, damage on the teeth flanks,
in addition to tooth breakage at the root of the tooth are one of the most frequent causes of gear failure.
This fatigue failure of the tooth decides the reliability of the gear. However, by introducing stress relieving
features to the gear, the points of stress concentration can be decreased which enhances life of gear. A study is
done on spur gear with involute profile by adding stress relieving features of different shapes and best among
them is proposed.

III. Gear Nomenclature:

Pitch surface: The surface of the imaginary rolling cylinder that replaces the toothed gear. Pitch circle: A
normal section of the pitch surface.
Addendum circle: A circle bounding the ends of the teeth, in a normal section of the gear. Dedendum circle or
Root circle: The circle bounding the spaces between the teeth, in a normal section of the gear.
Fig 1 Involute Spur gear
Addendum: The radial distance between the pitch circle and the addendum circle. Dedendum: The radial
distance between the pitch circle and the root circle.
Clearance: The difference between the Dedendum of one gear and the Addendum of the mating gear.
Face of a tooth: That part of the tooth surface lying outside the pitch surface. Flank of a tooth: The part of the
tooth surface lying inside the pitch surface. Top land: The top surface of a gear tooth.
Bottom land: The bottom surface of the tooth space.

Circular thickness: The thickness of the tooth measured on the pitch circle. It is the length of an arc and not
the length of a straight line.
Tooth space: The space between successive teeth.
Width of space: The distance between adjacent teeth measured on the pitch circle.
Backlash: The difference between the tooth thickness of one gear and the tooth space of the mating gear.
Circular pitch (P): The width of a tooth and a space, measured on the pitch circle. It is equal to the pitch
circumference divided by the number of teeth.
Diametrical pitch (P): The number of teeth of a gear per unit pitch diameter. The diametric pitch is hence the
number of teeth divided by the pitch diameter.
Module (M): Pitch diameter divided by number of teeth. The pitch diameter is usually specified in millimetres.
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Fillet Radius: The small radius that connects the profile of a tooth to the root circle.
Base circle: An imaginary circle used in involute gearing to generate the involutes that form the tooth profiles.
Contact Ratio: The average number of gear tooth pairs in contact on a pair of meshing gears.

Fig 2 Meshing of Gear teeth

Pitch point: The point of tangency of the pitch circles of a pair of mating gears.Common tangent: The line
tangent to the pitch circle at the pitch point.
Line of action: A line normal to a pair of mating tooth profiles at their point of contact. Path of contact: The
path traced by the contact point of a pair of tooth profiles.
Pressure angle: The angle between the common normal at the point of tooth contact and the common tangent
to the pitch circles. Pressure angle is also the angle between the line of action and the common tangent.
Crowning: Grinding of tooth edges to prevent edge loading is known as crowning.
4. Spur gear:

Fig 3 Spur Gear

Spur gears are the most common type of gears. They are used to transmit rotary motion between parallel shafts
i.e., they are usually cylindrical in shape, and the teeth are straight and parallel to the axis of rotation.
Sometimes many spur gears are used at once to create very large gear reductions. Spur gears are used in many
devices but not in cars as they produce large noises.

IV. Conjugate action:

Mating gear teeth against each other to produce rotary motion are similar to cams. When the tooth
profiles are designed so as to produce a constant angular-velocity ratio during meshing, they are said to have
conjugate action. A geometric relationship can be derived for the form of tooth profiles to provide conjugate
action which is summarized as Law of Gearing as follows:
“A common normal to the tooth profiles at their point of contact must, in all positions of the contacting
teeth, pass through a fixed point on the line-of-centres called the pitch point."
Any two curves or profiles engaging each other and satisfying the law of gearing are conjugate curves.
The angular-velocity ratio between the two arms is inversely proportional to their radii to the point P.
Circles drawn through point P from each centre are called pitch circles, and the radius of each circle is called
the pitch radius. Point P is called the pitch point
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V. Tooth profile:
Cycloid AL:
The cycloid AL gear profile is a form of toothed gear used in mechanical clocks. The gear tooth profile
is based on the epicycloids and hypocycloid curves, which are the curves generated by a circle rolling around
the outside and inside of another circle, respectively. An advantage of the cycloid AL teeth over the involute
one is that wear of Cycloid AL tooth is not as fast as with involute tooth. For this reason, gears transmitting
very large amount of power are sometimes cut with cycloid AL teeth.

Fig 4 Conjugate action

1)Since the cycloid AL teeth have wider flanks, therefore the cyclical gears are stronger than the involute gears,
for the same pitch. These are preferred for cast teeth.
2) In cycloid AL gears, the contact takes place between a convex flank and concave surface, where as in
involute gears, the convex surface are in contact. This condition results in less wear in cycloid AL wear and
however the difference in wear is negligible.
3) The interference in cycloid AL gears does not occur at all. Though there advantages of cycloid AL gears they
are outweighed by the greater simplicity and flexibility of the involute gears.

Involute:
The involute gear profile is the most normally used system for gearing. In an involute gear, the profiles
of the teeth are involutes of a circle. The involute of a circle is the spiralling curve traced by the end of an
imaginary taut string unwinding itself from that stationary circle called the base circle. In involute gear design,
contact between a pair of teeth occurs at a single instantaneous point. Rotation of the gears causes the location
of this contact point to move across the respective tooth surfaces.

Fig 5 Involute profile of gear tooth

1. Involute teeth are very easy to manufacture and the actual distance between the centres may deviate
slightly from the theoretical distance without affecting the velocity ratio or general performance. Because of this
distinct advantage, gears with involute profile teeth are used more than those with cycloid AL teeth.
2. In involute gears, the pressure angle, from the start of the engagement of teeth to its end remains
constant. It is necessary for smooth running and less wear of gears. But in cycloid AL gears, the pressure angle

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is maximum at the beginning of engagement, reduces to zero at pitch point, starts increasing again and becomes
maximum at the end of engagement. This does not yield smooth running of gears.
3. The face and flank of involute teeth are generated by a single curve where as in cycloid AL gears,
double curves are required for the face and flank respectively.
4. Thus the involute teeth are easy to manufacture than cycloid AL teeth. The only disadvantage of
involute teeth is that the interference occurs with pinions having smaller number of teeth.
5.
VI. Finite Element Method
FEM: Finite Element Method (FEM) is a numerical technique for finding approximate solutions to
boundary value problems. A boundary value problem is a differential equation together with a set of additional
restraints, called boundary conditions. FEM uses various methods to minimize an error function and produce a
stable solution. Analogous to the idea that connecting many tiny straight lines can approximate a larger circle,
FEM encompasses all the methods for connecting many simple element equations over many small sub
domains, named finite elements, to approximate a more complex equation over a larger domain.
The subdivision of a whole domain into simpler parts has several advantages:
1. Accurate representation of complex geometry
2. Inclusion of dissimilar material properties
3. Easy representation of the total solution
4. Capture of local effects.
A typical work out of the method involves dividing the domain of the problem into a collection ofsub-
domains, with each sub-domain represented by a set of element equations to the original problem, followed by
systematically recombining all sets of element equations into a global system of equations for the final
calculation. The global system of equations has known solution techniques, and can be calculated from initial
values of the original problem to obtain a numerical answer.

7.1 Calculix:
Calculix is an open source finite element analysis application with an explicit and implicit solver and a
pre/post processor. It is a package designed to solve field problems. The method used is the finite element
method. With CalculiX Finite Element Models can be build, calculated and post-processed. The pre- and post-
processor is an interactive 3D-tool. The solver is able to do linear and non-linear calculations. Static, dynamic
and thermal solutions are available. Both programs can be used independently. Because the solver makes use of
the ABAQUS input format it is possible to use commercial pre-processors as well. In turn the pre- processor is
able to write mesh related data. Calculix is a very powerful tool of analysis, highly configurable allowing the
user to have complete control over the analysis, with more than 18 types of analysis covering most fields of
study finite element. Calculix's user can modify any variable on the analysis at discretion, the huge amount of
information and documentation on the web make CalculiX a great alternative for the development of research
projects.
VII. CalculiX Graphics (CGX):
CalculiX user interface is CGX program, which allows one to create the geometric model, making the
mesh, generate the loads and constraints and post-processing of information. Although it contains a graphical
display area and certain model selection activities are made possible through the computer mouse, most of the
work is done by typing text on a command line. Therefore it must know the name and syntax of each command.
Despite this the quality of documentation and logic handled at the command causes the program is easily
manageable, where skilled users might include their own functions. For example someone may need his own
functions to manipulate the result-data or he may need an interface to read or write his own results format.
After the analysis is completed (on CCX), the results can be visualized by calling the CGX program again in an
independent session. The program is primarily controlled by the keyboard with individual commands for each
function. Only a subset of commands which are most important for post-processing is also available through a
pop-up menu. Also, a cut through the model can be done which creates a section and it is possible to zoom
through the model. Shaded animations of static and dynamic results, the common colour plots and time history
plots can be created.

VIII. AUTO-CAD:
AutoCAD is a software application for computer-aided design (CAD) and drafting. The software
supports both 2D and 3D formats. The software is developed and sold by Autodesk, Inc. It had become the most

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ubiquitous design program in the world, utilizing functions such as polylines and curve fitting. The AutoCAD
software is now used in a range of industries, employed by architects, project managers and engineers.
AutoCAD was initially derived from a program called Interact, which was written in a proprietary language.
The first release of the software used only primitive entities such as polygons, circles, lines, arcs and text to
construct complex objects.
DWG (drawing) is the native file format for AutoCAD and a basic standard for CAD data
interoperability. The software has also provided support for design Web format (DWF), a format developed by
Autodesk for publishing CAD data.

IX. Geometry creation:

Fig 6 .teeth Spur gear used for analysis

Fig. 7. Extruded Spur gear

Fig.8 Spur gear with aero-fin hole

X. GMSH:
GMSH is a three-dimensional finite element mesh generator with a build-in CAD engine and post-
processor. Its design goal is to provide a fast, light and user-friendly meshing tool with parametric input and
advanced visualization capabilities. GMSH is built around four modules: geometry, mesh, solver and post-
processing. Geometry module is used to define geometrical objects such as points, lines, surfaces and volumes
while mesh module is used to create mesh (nodes and element topology). All instructions of the modules are
prescribed either interactively using the graphical user interface (GUI) or in text files using GMSH's own
scripting language.

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11.1. Finite Element Mesh Generation:

A finite element mesh is a positioning of a given subset of the three-dimensional space by elementary
geometrical elements of various shapes. The mesh generation is performed in the bottom-up flow i.e., lines are
discretized first; the mesh of the lines is then used to mesh the surfaces; then the mesh of the surfaces is used to
mesh the volumes. In this process, the mesh of an entity is only constrained by the mesh of its boundary. For
example, in three dimensions, the triangles discretizing a surface will be forced to be faces of tetrahedral in the
final 3D mesh only if the surface is part of the boundary of a volume. This automatically assures the conformity
of the mesh. Every meshing step is constrained by a “size field” (sometimes called “characteristic length field”),
which Gmsh 2.7 prescribes the desired size of the elements in the mesh. This size field can be uniform or
specified by values associated with points in the geometry.

Gmsh is good at:

1. Generating 1D, 2D and 3D simplicial finite element meshes for CAD models in their native format
2. Specifying target element sizes accurately. It provides several mechanisms to control the size of
elements in the final mesh: through interpolation from sizes specified at geometry points and using flexible
mesh size fields.
3. Running on low end machines and machines with no graphical interface.
4. Visualizing and exporting computational results in great variety of ways.
5. Creating simple extruded geometries and meshes with the help of respective commands.
The problem of stress concentration is solved by removing material in the path of stress flow analogy.
When the material is removed in the path of flow analogy, the lines of force will travel uniformly. In our
experiment, the material is removed in the shape of an aerodynamic fin which decreased the maximum principal
stress at the fillet.

Fig 9.Spur gear with linear brick meshing

Fig 10.Spur gear loaded at HPSTC

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XI. Problem definition:
A gear having specifications of Module (M) =2, No. of teeth(N)=25 to study and experiment is chosen
from our reference thesis. A load of 89MPa as given in thesis is applied at the highest point of contact of gear
teeth. The stress at root fillet region is of the value 168Mpa which is much higher than the actual applied load.
Then the stress relieving features are introduced, which are the circular holes of different dimensions which
decreased the stress at the fillet to 124MPa. The stress relieving features used in the gear till date are circular
holes or the combination of circular and elliptical holes. Here we have tried an aerodynamic structured hole in
the path of stress flow analogy and the results are analysed. A segment of three teeth is considered for analysis
and stress relieving features of various sizes are introduced on gear teeth at various locations.

12.1. Laminar flow analogy:

For relieving stress concentration in gears conventional methods used are making Fillets, Notches and Holes.
1. Flow analogy with circular-shaped hole
2. Flow analogy with square-shaped hole.
3. Flow analogy with notch
The flow analogy is used to visualize the stress concentration. It gives us a physical picture of why and
where stress concentration exists and it can be used as a tool to decrease stress concentration. The path of flow
analogy in gear starts from highest point of application of load and ends at the root fillet of the tooth. This
indicates that lines of force travel from contact point to root fillet, with gradual decrease in width of the flow
pattern. So, the stress concentration is more at the fillet region which causes breakage of the tooth. The problem
of stress concentration is solved by removing material in the path of stress flow analogy. When the material is
removed in the path of flow analogy, the lines of force will travel uniformly. In our experiment, the material is
removed in the shape of an aerodynamic fin which decreased the maximum principal stress at the fillet.

12.2. Significance of Aero-fin hole:

The shape of aero-fin selected for this study is such that it modifies the stress flow into a smoother
way, i.e., smoother flow of stress is achieved best by an aero-fin type of design because the curvy nature of this
helps stress flow lines of stress to find a fluent path without any interruptions, the shape becomes narrowed
towards the fillet end which will help the stress lines to flow smoothly to the fillet without increasing stresses.

XII. Results: Stresses & Displacements of analysed gears

The gear without hole is examined to determine the maximum stress at the fillet and then theaero-fin
hole is introduced to gear. The position and size of the aero-fin hole can be varied by changing input values of
center of one of the arcs of hole and scaling factor using Parametrization in Gmsh. Now, the gear is
experimented with different modifications done to the aero-fin hole by varying the parameters mentioned
above. The stresses and displacements are calculated and analyzed so that the maximum stress at the fillet is
reduced which is the main aim of this project.
The co-ordinates of a focus point. It is considered as the centre of aero-fin hole which is used for
transformation of entire hole.

Fig 11.Centre of aero-fin hole

13.1. Stress and displacement in Normal Gear:

The maximum stress at the fillet is 168Mpa which much higher compared to the applied load on the gear.

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According to the results tabulated above, the decrease in stress is 50.23%, whereas in the reference
thesis stress is reduced by 24.07%. From this it can be inferred that aero-fin hole serves better as a stress
relieving feature compared to circular hole.

Stress and displacement in Gear (with aero-fin hole):

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The maximum stress at the fillet is 98.3Mpa after the introduction of aero-fin hole with a scaling factor of 0.75.

13.2. Graphs:
From the above graph it can be concluded that as the size of hole decreased, stress induced in the gear
decreased significantly due to the modulation of hole in the stress flow direction.

From this graph, as the scaling decreased, the displacement also decreased. This is because as the hole size is
less, material will be more due to which gear will be stiffer and finally displacement will be lower.

XIII. Conclusion
The main aim of the above study is to relieve stress from the maximum value to as minimum as
possible. So the highest point of contact of teeth is selected as pressure application point which causes highest
stress.
Stress relieving feature having a shape of aero-fin is used in the path of stress flow which helped to
regulate stress flow by redistributing the lines of force. This also yielded better results when compared to
elliptical and circular holes.
In this study, the best result is obtained by introducing aero-fin hole at (38.7653, 65.4083, 0) and
having scaling factor of 0.6. The result displayed a stress reduction by 50.23% and displacement reduction by
45.34%.

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14.1. Scope for further work:
1. Some more positions of the aero-fin shape can be experimented.
2. This can be extended to Bi-directional gears.

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