Design of Spur Gear Using Composite Material

DESIGN AND ANALYSIS OF THE COMPOSITE SPUR GEAR

The spur gear is simplest type of gear manufactured and generally used for transmission of rotary motion between parallel shafts. The spur gear is the first choice option for gears except when high speeds, loads and ratios direct towards other options. Other gear types may also be preferred to provide more silent low-vibration operation. A single spur gear is generally selected to have a ratio range of between 1:1 and 1:6 with a pitch line velocity up to 25 m/s [6]. The spur g ear has an operating efficiency of 98-99%. The pinion is made from a harder material than the wheel.

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Design Modeling, Simulation of Spur Gear; Analysis of Spur Gears

The ability to create something out of nothing makes design one of the most exciting aspects of engineering. To be successful, design engineer require abroad set of talents include knowledge creativity, people skill and planning ability .Engineers use CAD to create two− and three−dimensional drawings, such as those for automobile and airplane parts, floor plans, and maps and machine assembly. While it may be faster for an engineer to create an initial drawing by hand, it is much more efficient to change and adjust drawings by computer. In the design stage, drafting and computer graphics techniques are combined to produce models of different machines. Using a computer to perform the six−step'art−to−part' process: The first two steps in this process are the use of sketching software to capture the initial design ideas and to produce accurate engineering drawings. The third step is rendering an accurate image of what the part will look like. Next, engineers use analysis software to ensure that the part is strong enough shown in fig;1; .Step five is the production of a prototype, or model CAD began as an electronic drafting board, a replacement of the traditional paper and pencil drafting method. Over the years it has evolved into a sophisticated surface and solid modeling tool. Not only can products be represented precisely as solid models, factory shop floors can also be modeled and simulated in 3D. It is an indispensable tool to modern engineers

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Contact Stress Analysis of Composite Spur Gear using Photo Stress Method and Finite Element Analysis

watches to very large mechanical units like lifting devices and automotives. Gear is one of the most critical component in a mechanical power transmission system and in most industrial rotating machinery. New gear design is needed because of the increasing performance requirement.Gear teeth normally fail when load is increased above certain limit. Therefore it is required to explore alternate material for gear manufacturing. Composite materials provide adequate strength with weight reduction and they have emerged out as a better replacement for metallic gears. The contact stress in the mating gear is the key parameter in gear design. This paper represent contact stress analysis of steel gear and composite gear using Hertz equation and by Finite Element Analysis using Ansys 16.0 Workbench. Also experimental stresses are calculated using Photo-Stress Method.In this work, Aluminium Silicon Carbide is used as a gear material. When compared, the results of both theoretical method and FEA show a good degree of agreement with experimental results.

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DESIGN & ANALYSIS OF SPUR GEAR USING DIFFERENT MATERIAL BY ANSYS SOFTWARE

In the gear design the bending stress and surface strength of the gear tooth are considered to be one of the main contributors for the failure of the gear in a gear set.In this paper contact stresses are calculated by using analytical method as well as Finite element analysis. To estimate bending stress modified Lewis beam strength method is used. CATIA solid modeling software is used to generate the 3-D solid model of spur gear. ANSYS workbench software package is used to analyze the bending stress. Contact stresses are calculated by using modified AGMA contact stress method. In this also CATIA modeling software is used to generate contact gear tooth model. ANSYS 19.2 software package is used to analyze the contact stress. Finally these two methods contact stress results are compared with each other.

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Design and Analysis of Snap fit joint in Plastic part

New products drive business. To remain competitive, industry is continually searching for new methods to evolve their products. To address this need, we use reverse engineering methodology. We start by formulating the customer needs, followed by reverse engineering, creating a functional model through teardowns. The functional model leads to specifications that match the customer needs. Depending upon required redesign scope, new features are possibly conceived, or not. Next, models of the specifications are developed and optimized. The new product form is then built and further optimized using designed experiments. In this research paper, we apply reverse engineering process on spur gear by doing computer aided modeling, design and analysis.

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DESIGN & STATIC ANALYSIS OF SPUR GEAR USING DIFFERENT MATERIAL BY ANSYS SOFTWARE

In the gear design the bending stress and surface strength of the gear tooth are considered to be one of the main contributors for the failure of the gear in a gear set. Thus, the analysis of stresses has become popular as an area of research on gears to minimize or to reduce the failures and for optimal design of gears In this paper contact stresses are calculated by using analytical method as well as Finite element analysis. To estimate bending stress modified Lewis beam strength method is used. CATIA solid modeling software is used to generate the 3-D solid model of spur gear. ANSYS workbench software package is used to analyze the bending stress. Contact stresses are calculated by using modified AGMA contact stress method. In this also CATIA modeling software is used to generate contact gear tooth model. ANSYS software package is used to analyze the contact stress. Finally these two methods contact stress results are compared with each other.

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Review on Analysis and Modification of Spur Gear Design

Abstract— This paper present the Review on Analysis and modification of spur gear design and explain the design the spur gear and dimension specification. To design the spur gear to study the weight reduction and stress distribution for cast steel and composite materials. Gearing is one of the most critical components in mechanical power transmission system, and in most industrial rotating machinery. Its have a involving modern design, specific character, specific materials, with consideration of analysis of force and its mechanical properties. These approach for modern spur design developing the tooth profiles with modified the shape and improving dimension. Spur gear is cylindrical shaped gear in which the teeth are parallel to the axis. It is easy to manufacture and it is mostly used in transmitting power from one shaft to another shaft up to certain distance & also used to vary the speed & Torque. the main purpose of modern spur gear design it increases the power transmitting capacity and also improves the efficiency of power transmission.

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Design and analysis of NANO composite spur gear

Gears are machine elements used to transmit motion and power between rotating shafts by means of progressive engagements of projections. Gears have wide variety of applications. Their application varies from watches to very large mechanical units like the lifting devices and automotives. Engineering components made of composite materials find increasing applications ranging from space craft to small instruments. Overwhelming advantages such as light weight, higher dimensional stability and minimal attack by environment when compared with other ordinary mild steel gears. Modern level advanced polymer composite materials have opened a new level of soundless, lubricant free, high resilience and precision gearing in power and motion transmission. A proper understanding and prediction of gear failure is an important pre-requisite for any reliable application. In this project, a spur gear is designed using advanced modelling software (pro-engineer) and is meshed and analyzed using analysis software Abaqus 6.10 by the application of torque load. Two types of analysis are carried out using the software namely the static stress analysis and modal analysis. In static stress analysis tooth contact of a pair of spur gear system is analyzed as a body contact in three dimensional co-ordinates. The analysis consists of one loading condition to apply torque load on driving gear by constraining all degrees of freedom of driven gear. The hexagonal element model is meshed with in such a way that the elements around the gear teeth are fine and coarse at other places. The three dimensional elemental stresses and displacement magnitude are found out. Using modal analysis, the natural mode shapes and frequencies of composite gears is determined under free vibration. The interpretation of Eigen values which come from solving the system are that they represent the frequencies and corresponding mode shapes. The analysis is thus carried out making a comparison for a mild steel spur gear and carbon fibre / epoxy resin composite spur gear. The results in the variation of three dimensional stresses, displacement, frequencies and Eigen values are plotted and viability to manufacture such gears is predicted.

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Typical Stress & Deflection Analysis of Spur gear in Spur Gear Assembly

The available gear design software's are mathematical in nature for the proper modelling of the involute curve and the tooth profile generated from the curve. Dedicated gear design programs perform the calculations, which are necessary to create the true profile of the gear tooth, but this is a tedious and time-consuming operation. However, CAD/CAM applications can do this in seconds to generate a correct involute tooth profile quickly and easily due to their graphical nature. They are graphical modelling tools and there are a finite number of calculations they can perform and a finite number of points they plot along the involute curve.

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Modeling and Stress Analysis of Composite Material for Spur Gear under Static Loading Condition

Gear evaluation is one of the most vast troubles within the device elements idea mainly in the discipline of gear layout and tools production. Many of the researchers have proposed several ideas for tools layout optimization to enhance the overall performance of gear structures. S. Jyothirmai, et.Al., [1] mentioned "A Finite Element Approach to Bending, Contact and Fatigue Stress Distribution in Helical Gear Systems" objective of paper is comparative observe on helical equipment design and its overall performance primarily based on diverse overall performance metrics via the finite detail analysis and Theoretical evaluation by AGMA preferred. Than after FEA & theoretical results as compared to every different. J. Venkatesh, et.Al., [2] mentioned "Design and Structural Analysis of High Speed Helical Gear Using Ansys" additionally commenced the techniques that used to calculating the Bending and Contact stresses of involute helical gear pair.

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The Effect of Tooth Thickness on Root Stress of Internal Spur Gear Mechanism

In literature, there are various publications about different kinds of tooth designs to decrease root stress. One of these methods is using asymmetric gear that it has different pressure angle on drive and coast sides. With increasing pressure angle, the stress levels decrease [1-2]. Yılmaz et al. investigated effect of changing cutter tip radius on external and internal spur gears. When tip radius is increased, the stress values decrease [3-4]. Another method is to use artificial curves. Spitas et al. offered circular curve to reduce stress. However it is just effective when tooth number is under the 17 [5]. Zou et al. conducted an optimization study to reach an optimum curve. With specified curve, the stress values decrease approximately 20% [6]. Using different tooth thicknesses from standard value is novel approach. Sekar and Muthuveerappan conducted finite element analysis to obtain the effect of tooth thickness on stress of external spur gear mechanisms. Balanced stress values are determined for given teeth number, pressure angle and profile shifting coefficient [7].

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Comparative Modal analysis of conventional spur gear with modified involute spur gear

Athisaya and et al. (2014) explores the development of composite automotive gear box with optimum design and composite material selection at conceptual design stage for weight reduction to get better fuel efficiency with fulfilling needs of anti-fade characteristics, less power loses due to weight, corrosion resistant design and more consolidated design. The modal analysis is carried out to know the natural frequencies and mode shapes with the composites material gearbox.

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A REVIEW ON ANALYSIS OF SPUR GEAR

This review paper gives a detailed approach to spur gear design, analysis and manufacturing. Key design parameters are investigated in accord with industry standards and recommended practices for use. A final gear design is proposed and analyzed to show that proper margins of safety have been included in the design. In this report we try to cover some of the methods of analytical method of designing a spur gear, and FEM approach, and prediction of crack in gear teeth. Using simulator setup experimental result can be derives and necessary changes can be acceptable.

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A STUDY PAPER ON ANALYSIS OF SPUR GEAR

Shuting Li et al. [20] in this paper сontemplated the strategy for сorreсt bending quality and сontaсt quality estimations of a thin walled outfit at fast by utilizing FEM s/w. It was disсovered that when adapt speed surpasses 10000 rpm the radial load-distorted thin-walled equip effeсtsly affeсts tooth сontaсt design, tooth surfaсe сontaсt stress, root bending stress and tooth staсk sharing proportion. The figuring of quality outline of a fast thin-walled outfit issue has not been understood, but rather gives the thought, strategy and ventures of the сount for this issue. [2008]

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MODELING & STATIC ANALYSIS OF SPUR GEAR

In this we execute modal analysis to calculate the deformations at different frequencies and stress with deformations induced by applying force on tooth. The frequencies and natural mode shape results are obtained by modal analysis under free vibration. The frequencies and related mode shapes are represented by the Eigen values which came by solving problems. The analysis is thus carried out making a comparison for a Cast Iron, structural steel spur gear and carbon fibre epoxy resin composite spur gear.

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Vibration Analysis of Spur Gear FEA Approach

Abstract— Gears are used for a wide range of industrial applications. They have varied application starting from textile 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. 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 is one of the most frequent causes of gear failure. This fatigue failure of the tooth decides the reliability of the gear. In this paper, spur gear made up of EN9 material is designed and mode shape of respective gear is found out.

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The Design and Prototype Manufacture of a Planetary Gear Reducer

In the past, planetary gear trains were the subjects of intensive researches directed at kinematic analysis [1-5], kinematic design [6-13], and meshing efficiency analysis [14-19]. The purpose of this paper is to propose a planetary gear reducer with reduction ratio Rr=4 for industry purpose. The results of this paper can be used as a reference for engineers to design all kinds of planetary gear reducers. The research result can also provide the application experiences for the transmission design practice course.

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Static & Dynamic Analysis of Spur Gear using Different Materials

V. Siva Prasad et al [4]. This paper describes design and analysis of spur gear and it is proposed to substitute the metallic gears of sugarcane juice machine with polymer gears to reduce the weight and noise. A virtual model of spur gear was created in PRO-E, Model is imported in ANSYS 10.0 for analysis by applying normal load condition. The main purpose of this paper to analysis the different polymer gears namely nylon, polycarbonate and their viability checked with counterpart metallic gear like as cast iron. Concluding the study using the FEA methodology, it can be proved that the composite gears, if well designed and analysed, will give the useful properties like as a low cost, noise, weight, vibration and perform its operation similar to the metallic gears. Based on the static analysis Nylon gears are suitable for the application of sugarcane juice machine under limited load condition in comparison with cast iron spur gears.

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Stress and Reduction Analysis of a Spur Gear Tooth

762 Sorin Cănănău-Based [6] on an exact geometry design of the involute gear tooth, a set of profile gears is obtained in order to calculate the 2D contact. A stress analysis was performed for CAD profiles results using the finite element procedure. The paper investigates the 2D analysis versus 3D analysis for stress in the root region of teeth. By this approach, is also investigated the influence of non-uniform load along contact line to the fillet stress. Ali Raad Hassan [7] did a research study in which Contact stress analysis between two spur gear teeth was considered in different contact positions, representing a pair of mating gears during rotation. A programme has been developed to plot a pair of teeth in contact. Each case was represented a sequence position of contact between these two teeth. The programme gives graphic results for the profiles of these teeth in each position and location of contact during rotation. Finite element models were made for these cases and stress analysis was done. The results were presented and finite element analysis results were compared with theoretical calculations, wherever available. The idea of using holes to reduce stresses is not a new one. In 1990, Dippery [7] experimented with the use of supplementary holes in a structure as a method of reducing the stress concentration that was already present. His result showed that stress concentration reductions are possible in a generic shape using holes as stress relief.

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Design of Spur Gear Using Composite Material

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