© 2021 JETIR August 2021, Volume 8, Issue 8 www.jetir.
org (ISSN-2349-5162)
DESIGN AND ANALYSIS OF SPUR GEAR
USING ANSYS
R. Kiran Kumar
Assistant professor, Dept. of Mechanical Engineering, SRK Institute of Technology, Enikepadu, Vijayawada-
08, A.P, India
R. Karun Kumar
Assistant professor, Dept. of Mechanical Engineering, SRK Institute of Technology, Enikepadu, Vijayawada-
08, A.P, India
Y. Durga Bhavani
Assistant professor, Dept. of Mechanical Engineering, SRK Institute of Technology, Enikepadu, Vijayawada-
08, A.P, India
Abstract:In the present work, Static analysis is performed to determine the Factor of Safety and Von-mises stresses. The
analysis is done by considering different materials for gears like Structural Steel, AlBeMet – 162, AISI 1080 Steel, Carbon epoxy
fiber, and results are compared. The aim is to replace the cast iron spur gear or steel spur gear with these composites. These
composites have better strength, low weight, and damping characteristics, and better performance which often exhibits less wear
rate.
1.INTRODUCTION
A Gear is a machine element is used to transmit motion and power between rotating shafts using progressive
engagements of projections. They have a wide variety of applications which varies from watches to very large mechanical units
like lifting devices and automotive. Engineering components made of composite materials find increasing applications ranging
from spacecraft to small instruments. These Gears may predominate as the most effective means of transmitting power in future
machines due to their high degree of reliability and compactness. Husaini and DM Dawud (1) investigated the cause of the spur
gear fracture through numerical studies. Pradeep Kumar Singh, ManwendraGautam, Gangasagar, Shyam Bihari Lal (2)
investigated to minimized the failures in gears by analysis of the problem during the design stage and creating a proper tooth
surface profile by using Ansys workbench software.
Sushovan Ghosh, Rohit Ghosh, Bhuwaneshwar Patel, Tanuj Srivastava, and Dr. Ravindra Nath Barman (3) reviewed the
static analysis of the spur gear in the existing automobile gearbox considering its material geometrical parameters and the
manufacturing processes. Shanmuga sundaram Sankar, Masanamuthu Sundar Raj, Muthusamy Nataraj (4) examined the tooth
failure in spur gears. Corrective measures are taken to avoid tooth damage by introducing profile modification in the root fillet.
Mrs. Shinde S.P., Mr. Nikam A.A, Mr. Mulla T.S.(5) reviewed the characteristics of spur gears in a gearbox that will be studied
using the linear Finite Element Method. In the Review Paper On Analysis Of Spur Gear,V. A. Gavali, C. P. Satav (6)discussed
that gears while transmitting the power generates high stresses at the mating positions over the teeth as they amend the rate of
rotation of the machine shaft. In the Project Report, Maximum Torque of combination threats for spur gear based on AGMA and
JGMA Standard by WU JIA HANG (7) investigation of the transformation curve of gearing safety is discussed.
Ms. Nilesh U. Patil, Mr. Sunil P. Chaphalkar, Mr. Gajanan L. Chaudhari (8) reviewed the Analysis of Spur Gear by using
Different Materials. Jillepalli Naresh Babu, (9)discussed the dynamic stress analysis mesh gear using Ansys software. B. Siva
kumar, I. Joe Michael discussed the Experimental results from testing the spur gear under a moment and the Analysis has been
carried out by optimizing the material such as carbon fiber high modulus. Prathamesh Surnis, Dr. Pravin Kulkarni (11)gives a
detailed and comprehensive procedure of material to be selected for a Spur Gear Design. K Senthilna than et al (12) designed and
analyzed of gear testing kit, for testing the load generation developed on the gear tooth through the brake drum.
Shanavas S. (13) discussed replacing the cast iron spur gear with carbon fiber epoxy composite spur gear. For that,
analytical and finite element methods are applied for determining bending stresses and contact stresses of the gear tooth. Nair Ajit
V (14) discussed the failures in gear teeth when the load is increased beyond a limit. Putti Srinivasa Rao, (15) discussed the
bending stress over the lower addendum of the spur gear, shear, and contact stresses by using the software tools like pro-e and
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ANSYS.
2. PROBLEM STATEMENT & METHODOLOGY:
The objective of the present work is to analyze the spur gear made up of different types of materials such as Structural
steel, AlBeMet – 162, AISI 1080 Steel, and Carbon fiber epoxy. First, the Spur Gear is designed in Dassault Systems and
assembled in CATIA V5, and analysis is conducted on ANSYS 19.2. The fixed support and torque are applied to the Spur Gear.
Static analysis is performed to obtain the Maximum Principal Stress, Equivalent Von-Misses Stress, and Total Deformation of
Spur Gear subjected to boundary condition, and then Torque is applied to the Spur Gear.The static analysis is performed by
applying a Torque of 225 N-m to the Frictionless support of the spur gear assembly for this Total Deformation and Equivalent
Von-Misses Stress is obtained. The same procedure is conducted for different materials like Structural Steel and AlBeMet – 162,
AISI 1080 Steel, and Carbon fiber epoxy. The results of Equivalent Stress Maximum Principal Stress and Total Deformation are
compared.
2.1 Geometry:
The dimensions of a spur gear are Pitch circle diameter (p.c.d) = 180mm,Number of teeth = 18, Outside circle diameter =
200mm, Circular pitch = 31.4mm, Dedendum circle diameter = 156.86mm, Dedendum = 11.57mm, Addendum = 10mm,
Module = 10mm, Fillet radius = 3.9mm, thickness of the tooth = 15.71mm, Face width (b) = 54mm
Fig 1: Design of Spur Gear Fig 2: Assembly of Spur gear
2.2 Design Calculations
TORQUE (T) = 13.8kg-m@2500rpm
POWER (P) = 2 x 3.14 x 2500 x T/60
P = 2 x 3.14 x 2500 x 138/60;
P = 36128
Watt Power (P) = 36.128 K Watt
Torque (T) = F x (d/2)
Where,
F-load,
d- Pitch circle diameter (z x m=180mm)
T= F x (d/2)
F = T/ (d/2)
F = 138000/90 Load
(F) = 1533.33N
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Tangential load, F =b x y x Pc x σb
Pc = 3.14 x module
Pc = 31.4mm
Y= Lewis form factor=0.134mm
b = face width = 54mm
Table 1: GEAR TOOTH PARAMETERS
Terms Symbols Terms Symbols
Module m Tooth Thickness s
Pressure Angle Α Reference Diameter d
Number of Teeth Z Tip Diameter da
Pitch P Root Diameter df
Tooth Depth h Center Distance a
Addendum ha Backlash j
Dedendum hf Tip and Root Clearance c
Pitch circle diameter (P.C.D) = z x m = 18 x 10 = 180mm
Base circle diameter (Db) = D cos α = 180 x cos20 = 169.145mm
Outside circle diameter = (z+2) x m= (18+2) x 10 = 200mm
Clearance = circular pitch/20 = 31.4/20 = 1.57mm
Dedendum = Addendum + Clearance = 10+1.57 = 11.57mm
Module = D/Z = 180/18 = 10mm
Dedendum circle diameter = P.C.D – (2 x dedendum) = 80 - (2 x 11.57) = 156.86mm
Fillet radius = Circular pitch/8 = 31.4/8 = 3.9mm
Pitch circle diameter (Pc) = m x z = 10 x 18 = 180mm
Hole depth = 2.25 x m = 2.25 x 10 = 22.5mm
Thickness of the tooth = 1.571 x 10 = 15.71mm
Face width (b) = 0.3 x 180= 54mm
Center distance between two gears = 180mm
Diametral pitch = Number of teeth/P.C.D= 18/180= 0.1mm
Whereas,
z = Number of teeth,
m = Module.
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2.3 Material properties:
The material properties of Structural steel, AlBeMet– 162, AISI 1080 Steel, and Carbon fiber epoxy are as given below.
Table 2: Mechanical properties
Material
Parameter Structural steel AlBeMet– 162 AISI 1080 Steel Carbon fiber epoxy
Density (g/m^-3) 7080 2070 7800 1600
Young’s Modulus(Pa) 2E+11 1.79E+11 2E+11 1e+10
Poisson’s ratio 0.3 0.17 0.285 0.3
Bulk modulus 1.66667E+11 9.0404E+10 1.5504E+11 8.3333e+09
Shear modulus 7.6923E+10 7.6496E+10 7.7821E+10 3.8462e+08
Tensile yield strength 2.5E+08 1.93E+08 9.05E+08 1.5e+09
(Pa)
Tensile ultimate 4.6E+08 2.85E+08 1.035E+09 3.5e+09
strength (Pa)
2.4Chemical Composition of Materials:
The chemical composition of Structural steel, AlBeMet–162,AISI 1080 Steel, and Carbon fiber epoxy is as given below
Table 3: Chemical composition of the Structural steel
Fe C Mn Si S
98% 0.10% 1.0% 0.15% 0.005%
Table 4: Chemical composition of the AlBeMet - 162
Al Be
0.38% 0.62%
Table 5:Chemical composition of the AISI 1080 Steel
C Fe Mn P Sn
0.88% 98.6% 0.9% 0.04% 0.05%
Table 6: Chemical composition of the Carbon fiber epoxy
Carbon Petroleum Pitch
90% 10%
2.5 Loading &Boundary conditions:
The following types of loads and boundary conditions are applied for the prediction of the response of the structure in
the static analysis. The driving Gear is fixed and a Torque of225 N-m is applied to the driven Gear.
2.6 RESULTS AND DISCUSSION
2.6.1 Fem Analysis of spur gear:
The spur gear is made up of steel material. The spur gear is designed as per dimensions and loads and boundary
conditions are applied. The static analysis of carried out and the following results are obtained from static analysis.
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Table 7: Maximum Principal Stress & Maximum Principal Elastic Strain
Maximum Principal Stress Maximum Principal Elastic Strain
Spur gear
Max (Pa) Min (Pa) Max(m/m) Min(m/m)
Structural Steel 9.618e+006 -8.8543e+005 5.7898e-005 -7.6877e-008
AlBeMet– 162 4.0977e+006 -4.7195e+005 2.011e-005 -6.7591e-008
AISI 1080 Steel 3.2938e+006 -4.5078e+005 1.5379e-005 0
Carbon fiber epoxy 2.7971e+007 -2.8538e+006 4.6102e-004 -3.3786e-007
Fig 3 Max Principal Stress of Structural Steel
Fig 4 Max Principal Stress of AlBeMet - 162
Fig 6 Maximum Principal Stress of Carbon fiber epoxy
Fig 5 Max Principal Stress of AISI 1080 Steel
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Fig 7 Maximum Principal Elastic Strain of Structural Fig 8 Maximum Principal Elastic Strain of AlBeMet - 162
Steel
Fig 10 Maximum Principal Elastic Strain of
Fig 9 Maximum Principal Elastic Strain of AISI Carbon fiber epoxy
1080 Steel
Figure 11 Maximum Principal Elastic Strain of Structural Steel and Carbon Epoxy
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Table 8 Equivalent Stress (Von-mises) & Equivalent Elastic Strain
Equivalent Stress Equivalent Elastic Strain
Spur gear (Von-mises)
Max (PA) Min(PA) Max(m/m) Min(m/m)
Structural Steel 1.4513e+007 3.0223e-004 1.0319e-004 1.7702e-014
AlBeMet - 162 4.1461e+006 0 3.9259e-005 0
AISI 1080 Steel 5.0459e+006 0 2.5847e-005 0
Carbon fiber epoxy 3.9125e+007 1.0428e-003 1.2781e-003 2.623e-014
Fig 12 Equivalent Stress of Structural Steel Fig 13 Equivalent Stress of AlBeMet - 162
Fig 14Equivalent Stress of AISI 1080 Steel
Fig 15Equivalent Stress of Carbon fiber
epoxy
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Fig 16 Equivalent Strain of Structural Steel Fig 17 Equivalent Strain of AlBeMet - 162
Fig 18 Equivalent Strain of AISI 1080 Steel Fig 19 Equivalent Strain of Carbon fiber epoxy
Fig 20 Equivalent Strain of AISI 1080 Steel
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Table 9 Total deformation& Factor of safety
Total deformation
Spur gear Factor of safety
Max(m) Min(m)
Structural Steel 1.0284e-006 0 15
15
AlBeMet - 162 9.3608e-007 0
15
AISI 1080 Steel 6.5168e-007 0
6.3898
Carbon fiber epoxy 6.7171e-006 0
Fig 21Total deformations of Structural Steel Fig 22 Total deformations of AlBeMet - 162
Fig 23 Total deformations of AISI 1080 Steel
Fig 24 Total deformations of Carbon Fiber Epoxy
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Fig25 The safety factor of Structural Steel Fig 26 The safety factor of AlBeMet - 16
Fig 17 The safety factor of AISI 1080 Steel
Fig 28 The safety factor of Carbon Fibre Epoxy
5.1 Conclusion:
In the present work, the analysis of spur gear made up of structural steel, ALBMet 162, AISI 1080 Steel, Carbone epoxy is
examined in the application of gearbox which is used in automobile vehicles through Ansys.
It was found that AlBeMet – 162,AISI 1080 Steel, and Carbon fiber epoxy has less stress-induced, strain and deformation
when compared with structural steel and gray cast iron.
The deformation and weight of the spur gears of these composite materials are less as compared to the structural steel.
The factor of safety remains mostly the same for structural steel and composite materials.
It was found that Carbone epoxy has got good resistance characteristics as compared to other materials.
So from these analysis results, we may conclude that the stress-induced and deformation of these composite materials is
less as compared to the steel spur gear.
In Static analysis, carbon epoxy materials have good vibration resistance comparing to other materials.
This study will help to understand more the behavior of the spur gear and gives information for the manufacturer to
improve the strength of the spur gear. It can help to reduce the cost and time required for the research and development of
new products.
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