Mote Sonali .A et.

al; International Journal of Advance Research, Ideas and Innovations in Technology

ISSN: 2454-132X
Impact factor: 4.295
(Volume 4, Issue 2)
Available online at: www.ijariit.com

FEM analysis of helical gear

Sonali A. Mote A. V. Gaur Ajit. B. Gujale
[email protected] [email protected] [email protected]
Brahmdevdada Mane Institute of Brahmdevdada Mane Institute of Swami Vivekanand Institute of
Technology, Solapur, Maharashtra Technology, Solapur, Maharashtra Technology, Gulwanchi, Maharashtra

ABSTRACT

In this paper the problem of the failure of gear in speed reduction gearbox developed by Laxmi Hydraulic Pump (LHP) Pvt
Ltd, Solapur is resolved by modifying or redesigning the gear and pinion using AGMA and FEM analysis Method. In the gear
design, the bending stress and surface strength of the gear tooth are considered to be one of the main contributors to the
failure of the gear. In this paper bending and contact, stresses are calculated by using the analytical method as well as Finite
Element Method. The software is used to generate the 3-D solid model of the helical gear. Ansys software package is used to
analyze the bending stress and contact stress. The main objective of this study has to investigate the stresses induced by gear
tooth profile. Finally, the results obtained by theoretical analysis and Finite Element Analysis are compared to check the
correctness. Estimated stress is used to calculate module of gear which can withstand easily at given loading conditions.

Keywords: Bending stress, Contact stress, Pinion, Helical gear, ANSYS method.
1. INTRODUCTION

One of the best methods of transmitting power between the shafts is gears. Gears are mostly used to transmit torque and angular
velocity. It is widely used because it is capable of transmitting power in a very small centre distance between two parallel shafts.
Gear transmission systems play an important role in many industries such as automobile industry. A pair of teeth in action is
generally subjected to two types of stresses- bending stresses inducing bending fatigue and contact stress causing contact fatigue.
Helical apparatus are vital parts for any transmission. The tooth bending stress and surface contact stress of these gears had always
been one of the major areas of research for scholars. The designing of a helical gear pair is a complex process. This can be
changed by minimizing bending stress and contact stress or by modifying the geometry or parameters of the gear tooth

2. LITERATURE REVIEW
Linhong Xu Leiming Li Yin Liu [3] has done work on “Stress Analysis and Optimization of Gear teeth .the operational
performance of gear regarding smoothness, quietness, wear and life span is largely affected by how gear and pinion teeth make
contact.teeth profile plays a very important role in influencing contact condition during gear transmission. In this paper a kind of
Modification of teeth profile,crowned teeth,is presented and analzed by using ANSYS. Analytic result are presented to demonstrate
the better performance of gear under heavy load in gear transmission and relationship between drum shaped size design and load.
B.Venkatesh, V.Kamala, and A.M.K.prasad [4] the stresses generated and the deflections of the tooth have been analyzed for
different materials. The results obtained by theoretical analysis and Finite Element Analysis are compared to check the correctness.
A conclusion has been arrived on the material which is best suited for the marine engines based on the results. Basically the project
involves the “design, modelling and manufacturing of helical gears” in marine applications. It is proposed to focus on reduction of
weight and producing high accuracy gears.
Arvind Yadav [5] has done his work on “Different types Failure in gears”. The objective of this paper to present their recent
development in the field of gear failure analysis. By the help of this paper we can know about different types of failure detection
and analyzing techniques which is used to reduce these failures from gears. The intention of this paper is not to provide detailed
description of the causes of gear failure but it focused on the different type’s methodology that is used by the various researcher in
the past recent year to find out causes of failure in gear and what is final result of that to reduce the failure in gear.

© 2018, www.IJARIIT.com All Rights Reserved Page | 1839

 Mote Sonali .A et.al; International Journal of Advance Research, Ideas and Innovations in Technology
Pawan kumar [6] Design and Thermal Analysis of Helical Gearbox the work presented here is the study of thermal analysis of a 3
stage helical gearbox. Firstly the design of the gearbox is done by empirical formulas. The 2D drawing is then drafted to a 3D
model by 3D modelling software. The thermal analysis is done for the temperature generated at the tip of the mating gears.
.Govind T Sarkar [7] The bending and surface stresses of gear tooth are major factor for failure of gear.. STRESS ANALYSIS OF
HELICAL GEAR BY FINITEELEMENT METHODThis paper investigates finite element model for monitoring the stresses
induced of tooth flank, tooth fillet during meshing of gears. The involute profile of helical gear has been modeled and the
simulation is carried out for the bending and contact stresses and the same have been estimated. To estimate bending and contact
stresses, 3D models for different helical angle, face width are generated by modeling software and simulation is done by finite
element software packages. Analytical method of calculating gear bending stresses uses bending equation and for contact stress
contact equation are used.
A.Y Gidado A.Y Gidado, I. Muhammad, A. A. Umar, [8] has done work on “Design, Modeling and Analysis of Helical Gear
According Bending Strength Using AGMA and ANSYS” there are two kinds of stresses in gear teeth ,root bending stresses and
tooth contact stresses. These two stresses results in the failure of gear teeth, root bending stress results in fatigue fracture and
contact stresses results in pitting failure at the contact surface. So both these stresses are to be considered when designing gears. In
this paper one of the principal failure modes are studied based on the calculation of bending stress. To estimate the bending stress,
three dimensional solid models for different face width are generated by Pro/Engineer that is a powerful and modern solid modeling
software and the numerical solution is done by ANSYS, which is a finite element analysis package. In this paper a helical gear was
modeled on Pro engineer wildfire 4.0 and stress analysis part is done on ANSYS 11.0.The results are then compared with both
AGMA and FEM procedures
J. Venkatesh , Mr. P. B. G. S. N. Murthy [9] 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 “Design and Structural Analysis of
High Speed Helical Gear “Using Ansys paper bending and 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.Ansys software package is used
to analyze the contact stress. Finally these two methods bending and contact stress results are compared with each other.
Babita Vishwakarma [10] Gears are one of the most critical components in mechanical power transmission systems. The bending
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,
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. “Finite Element Analysis of Helical Gear Using Three-Dimensional Cad Model “This paper investigates finite element
model for monitoring the stresses induced of tooth flank, tooth fillet during meshing of gears. To estimate bending and contact
stresses, 3D models are generated by modeling software CATIA V5 and simulation is done by finite element software package
ANSYS 14.0. Analytical method of calculating gear bending stresses uses Lewis and AGMA bending equation. Study is conducted
by varying the face width to find its effect on the bending stress of helical gear. It is therefore observed that the maximum bending
stress decreases with increasing face width. The stresses found from ANSYS results are compared with those from theoretical.
S. Jyothirmai, R. Ramesh, T. Swarnalatha, D. Renuka [11] the theoretical basis and performance characteristics of helical gear
design, a complete mathematical description of the relationship between the design parameters and the performance matrices is still
to be clearly understood because of the great complexity in their interrelationship. The objective of this work is to conduct a
comparative study on helical gear design and its performance based on various performance metrics through finite element as well
as analytical approaches. Helical gear are studied through finite element approach (FEA) in ANSYS and compared with theoretical
analysis of helical gear pair
3. PARAMETRIC MODELING OF HELICAL GEAR

The Five stage speed reduction gear box is devoloped by LHP is used to reduce the 1390 rpm of input motor to the output 1.1
rpm. There is failure of gear tooth of fifth stage gear due to incorrect design and having module 3.5 mm.
We redesign this gear and modified the module.While redesigning some of specifications like pressure angle, helix angle, face
width etc we kept same as previous design as per companies requirement.
Specification of Gearbox and gear:
Input power:- 0.37kw Gear teeth :-50 Input speed :-1390 rpm pinion teeth :-13
Final output:-1.1rpm Torque:-300kgm pressure angle: - 200 No. of stages:-5
Helix angle : 230 Face width :- 70mm

Material Properties:
20 MnCr5
Density – 7.8 gm/cm3 Ultimate tensile stregth- 1000Mpa
Yield Strength – 600 Mpa Youngs Modulus- 200000 Mpa
Hardness (BHN) – 601 Poisions ratio – 0.3

4. BENDING EQUATION
Bending failure and pitting of the teeth are the two main failure modes in a transmission gearbox.. This bending stress Equation
was derived from the Lewis formula.

© 2018, www.IJARIIT.com All Rights Reserved Page | 1840

 Mote Sonali .A et.al; International Journal of Advance Research, Ideas and Innovations in Technology

Bending Stress is given by,

Y is called the Lewis form factor. The Lewis equation considers only static loading and does not take the dynamics of meshing
teeth into account. The maximum stress is expected at the point which is a tangential point where the parabola curve is tangent to
the curve of the tooth root fillet called parabola tangential method.. The AGMA equation for bending stresses given by,
The AGMA equation for bending stresses given by,

Where Ka = Application factor, KS = Size factor, Km = Load distribution factor, KV = Dynamic factor, Ft = Normal tangential
load, J = Geometry factor

AGMA BENDING AND CONTACT STRESS ANALYSIS OF GEAR AND PINION

AGMA Bending Stress For pinion

W 1=

W1 = 0.4429 rad/s

i=

i= 3.8454

Torque:-
T 1=

=
T1=835.40X103N.mm

Ft =

Ft =

J=0.45, Overload Factor ko=1 , Km=1.3 , Kv=1.25

σb=

© 2018, www.IJARIIT.com All Rights Reserved Page | 1841

 Mote Sonali .A et.al; International Journal of Advance Research, Ideas and Innovations in Technology
Corrected bending fatigue strength of the pinion:
σe= σe,x kL KmKv kS KFKrkT
σe,= 0.5 X σut
= 0.5 x1000
=500

kL=1 for bending Km =1.2 from standard table Kv=1 for bending module less than 5
kS =1 KF=1
Kr =0.9 for 90% reliability kT =1 temp <1200

σe = 500x1x1x1x0.9x1x1x1.2
σe= 540
σb=
f.s as per given =1.4
=
σb = 385.71 N/mm2

σb=

385.71=
Mn=3.83 mm
mn 4mm

AGMA Bending Stress for Gear

As per AGMA standard equation the bending stresses are as:

Ft = 33636.6N
σb=261.33N/mm2

CONTACT STRESS
Contact stress causes deformation, plastic or elastic. The contact area will change depending on the magnitude of the contact
stress. Therefore, it is very imporant to calculate the actual stress at the point of contact, the so-called contact stress One of the
main gear tooth failure is pitting which is a surface fatigue failure due to repetition of high contact stresses occurring in the gear
tooth surface while a pair of teeth is transmitting power. Contact failure in gears is currently predicted by comparing the
calculated Hertz contact stress to experimentally determined allowable values for the given material.
The surface compressive stress (Hertzian stress) is found from the equation

© 2018, www.IJARIIT.com All Rights Reserved Page | 1842

 Mote Sonali .A et.al; International Journal of Advance Research, Ideas and Innovations in Technology
AGMA Contact Stress Equations:

AGMA Contact Stress

As already mentioned high contact stresses results in pitting failure of the gear tooth, it is necessary to keep contact stresses under
limit. As per AGMA contact stress equation are used as

cp=161 as per material b=70 Kv= 1 CR=1.5 l= 0.2345 Ko= 1 d= 56.59

contact stress = 702.49 N/mm2

5. FEM PACKAGE
ANSYS is the name commonly used for ANSYS mechanical, general-purpose finite element analysis (FEA) computer aided
engineering software tools developed by ANSYS Inc. ANSYS mechanical is a self contained analysis tool incorporating pre-
processing such as creation of geometry and meshing, solver and post processing modules in a unified graphical user interface The
following steps are used in the solution procedure using ANSYS
 The geometry of the gear to be analyzed is imported from solid modeler Pro/Engineer inIGES format this is compatible
with the ANSYS.
 The element type and materials properties such as Young's modulus and Poisson's ratio are specified.
 Meshing the three-dimensional gear model..
 The boundary conditions and external loads are applied.
 The solution is generated based on the previous input parameters.
 Finally, the solution is viewed in a variety of displays.

FEM Bending Stress Analysis:

In this section, the teeth bending stress of helical gear is calculated using ANSYS. For this purpose the modeled gear in
Pro/Engineer is exported to ANSYS as an IGES file and then an automatic mesh is generated

FEM RESULTS FOR BENDING STRESS OF PINION

© 2018, www.IJARIIT.com All Rights Reserved Page | 1843

 Mote Sonali .A et.al; International Journal of Advance Research, Ideas and Innovations in Technology

FEM RESULTS FOR BENDING STRESS OF GEAR-

FEM RESULTS FOR CONTACT STRESS

6. CONCLUSION
Theoretical design is carried out using standard design formulae as perAGMA procedure and carried out analysis by
ANSYS .The following.ttable.1shows the comparison the.theoretical design values With Ansys value

Bending Bending
No. of Difference
Name Stress by stress by
Teeth in %
AGMA Ansys
© 2018, www.IJARIIT.com All Rights Reserved Page | 1844
 Mote Sonali .A et.al; International Journal of Advance Research, Ideas and Innovations in Technology
Pinion 13 385.71 372.96 3

Gear 50 261.33 242.81 7

Contact Contact
Difference
Sr No. Name Stress stress
in %
byAGMA byAnsys
01 Assembly 702.49 700.09 0.3
of Gear and
pinion

The problem of gear failure of gearbox is due to incorrect module i.e 3.5 mm. By using AGMA and ansys the module of gear
should be 4 mm to perform well in given conditions.so we redesign the gear and modified module by changing the material.

7. ACKNOWLEDGEMENT
The authors would like to thanks Prof. Gaur A.V. from BMIT College of engineering Solapur, Solapur University for providing
his valuable guidance and encouragement for project work

8. REFERENCES

[1] V.B.Bhandari., Design of Machine Elements, Tata McGraw-Hill, 1994.

[2] R.S.Khurmi., Machine Design, S chand, 2005
[3] Linhong Xu Leiming Li Yin Liu ,Stress Analysis and Optimization of Gear teeth, International Conference on Measuring
Technology and Mechatronics Automation2009. pp -895-898.
[4] B.Venkatesh, V.Kamala, and A.M.K.prasad, Design, modeling and Manufacturing of helical gear,I international Journal Of
Applied Engineering Research, ISSN 0976-4259. Volume 1, No1, 2010. pp 103-114.
[5].Arvind Yadav, Different types Failure in gears-A Review,International.Journal.of.Science Engineering and Technology Research
(IJSETR) Volume 1, Issue 5, November 2012 , ISSN: 2278 – 7798,pp .86-92
[6] Pawan kumar ,Prof. M. Y. Patil ,Design and Thermal Analysis of Helical Gearbox, Research Paper,Volume : 2 ,Issue : 4 ,April
2013 ,ISSN No 2277 – 8160,, pp .139-140
[7]. Govind T Sarkar, Yogesh L Yenarkar and Dipak V Bhope, STRESS ANALYSIS of HELICAL GEAR .BY FINITE
ELEMENT METHOD, International Journal of mechanical Engineering and robotics research, ISSN 2278 -0149 Vol.2, No.4,
October 2013, pp-322-329
[8] A.Y Gidado, I. Muhammad, A. A. Umar, Design, Modeling and Analysis of Helical Gear According Bending Strength Using
AGMA and ANSYS, International Journal of Engineering Trends and Technology (IJETT) , ISSN: 2231-5381,Volume 8 Number 9-
Feb 2014,pp .495-499
[9]. J. Venkatesh, Mr. P. B. G. S. N. Murthy, Design and Structural Analysis of High Speed Helical Gear Using Ansys , Int. Journal
of Engineering Research and Applications ISSN : 2248- 9622, Vol. 4, Issue 3( Version 2), March 2014, pp.01-05.
[10] .Babita Vishwakarma, Finite Element Analysis of Helical Gear.Using.Three-DimensionalCadModel,
International journal of engineering science & Research Technology, ISSN: 2277-9655. April, 2014, pp .1952-1958.
[11]. S. Jyothirmai, R. Ramesh, T. Swarnalatha, D. Renuka, A Finite Element Approach to Bending, Contact and Fatigue Stress
Distribution in Helical Gear Systems, 3rd International Conference on Materials Processing and Characterisation (ICMPC 2014), pp
.907-918.

© 2018, www.IJARIIT.com All Rights Reserved Page | 1845