465

Analysis of stress and deformation in plastic

gears used in gerotor pumps
K Biernacki* and J Stryczek
Faculty of Mechanical Engineering, Wroclaw University of Technology, Poland
The manuscript was received on 21 December 2009 and was accepted after revision for publication on 12 March 2010.
DOI: 10.1243/03093247JSA630

Abstract: The mechanism of induction of stresses and deformations in plastic cycloidal gears
used in gerotor pumps has been analysed using the finite element method and the ABAQUS
program. It has been found that the gear system remains under the influence of the mechanical
load resulting from the torque on the pump shaft and the hydraulic load resulting from the
activity of pressure in the intertooth displacement chambers. It has also been discovered that
the intertooth forces and stresses are formed only in the part of the gear that can be referred to
as active. In the other part of the gear, forces and stresses do not occur, and the part can be
referred to as passive. Another finding of the research is that gear deformations occur such
that the teeth of the external gear are deformed and moved in the direction of the active part of
the mesh, and the teeth of the internal gear in the direction of the passive part. Thus, radial and
axial intertooth clearances are formed, which result in internal leakages in the pump, as well as
in lower working pressure and efficiency of the machine. A way of determining the load range
for plastic gears used in gerotor pumps has been specified. It has also been observed that the
loading of the pump should not result in reduced stresses sz higher than compressive stresses
sc equal to the plasticity limit Re of the plastic, that is, sz ( sc 5 Re. At the same time, the radial
clearance hr and the axial clearance ha should not exceed the extreme values hr max and ha max
assumed for a particular size of gerotor pump, that is, hr , hr max and ha , ha max .
Keywords:
1

gerotor pumps, cycloidal gears, plastics, finite element method, stress, deformation

INTRODUCTION

Gear pumps are basic energy generators in hydraulic

drive systems. There are three generations of gear
pumps:
(a) external toothing gear pumps;
(b) internal toothing gear pumps;
(c) gerotor pumps.
A fundamental design feature of gear pumps is the
internal cycloidal gear with the tooth difference
z2 2 z1 5 1. This feature gives the gerotor machines a
considerable advantage over internal and external
gear pumps, namely a very compact structure, a
smaller size, and lower weight. The intertooth
*Corresponding author: Faculty of Mechanical Engineering,
Wroclaw University of Technology, Lukasiewicza 7/9, Wroclaw
50-371, Poland.
email: krzysztof.biernacki@pwr.wroc.pl
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displacement chambers in the gerotor pumps have

a high volume, which enables a high efficiency of the
relatively small and lightweight units to be achieved.
The pumps work with a lower delivery pulse and
pressure than gear pumps, which results in a
reduction in noise while in operation. At the same
time, gerotor pumps are reliable and durable.
The history of gerotor pump development is long.
According to Pippenger and Dong [1], gerotors were
discussed back in the eighteenth and nineteenth
centuries. The first work on the subject was written
by Myron Hill, who in 1926 published a book entitled
Kinematics of Gerotors.
An important step in gerotor development was the
start-up of mass production of gerotor pumps by
Henry Nichols in the 1930s in the United States.
Another stage in gerotor machine evolution, in the
1950s, was the application of gerotor elements in
orbital motors by Lynn Charlson.
Research on gerotor elements at that time focused
on their geometry and kinematics, as well as on their
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K Biernacki and J Stryczek

possible applications in selected fluid power machines. Publications on the subject were rather rare
and unthorough, and the specialist knowledge was
protected by the manufacturers. An original approach to the subject was presented in 1948 by
Sannikow [2], who described the geometry and
kinematics of various gear types working in gerotor
machines. Another distinguished study of the problem of gerotors was published by Colbourne [3],
who presented possible applications of trochoids
(cycloids) of various types in the manufacture of
rotodynamic pumps. A different approach to the
geometry and kinematics of gerotors was presented
in studies by Stryczek [47]. Gerotors were treated as
gears with corrected and modified cycloidal profiles,
and their geometry and kinematics were described
by a uniform system of parameters: z was the tooth
number, m was the modulus, l was the tooth depth
ratio, and v was the correction coefficient.
In the 1970s and 1980s, new gerotor hydraulic
machines were produced in Germany, namely the
ring rotor pump presented by Scholler [8] and the MZ
planetary motor described by Wusthof and Schneider
[9]. The machines feature a higher working pressure
as well as volumetric and total efficiency, and they are
also quieter than the Nichols and Charlson machines.
Further development of gerotors was dictated by
the development of the theoretical fundamentals of
this machine group, and particularly on the development of hydraulic models. Bednarczyk and Stryczek
[10] formulated rules for designing the axial clearance
compensation in gerotor pumps, whereas Antoniak
and Stryczek [11] provided a model of flow in the
channels and internal clearances of gerotor pumps.
As a result of research, a gerotor pump featuring axial
clearance compensation, a high working pressure,
and volumetric efficiency, as well as a low-speed,
high-torque orbital motor with a double-gear gerotor
set of very high displacement (10 000 cm3/rev), was
made and described by Stryczek [12]. Italian engineers built a miniature gerotor pump featuring axial
and radial clearance compensation [13].
In order to take another step in gerotor machine
development, the gerotor elements had to be
strengthened. Research enabled the maximum gear
load to be found. Mechanical and hydraulic loads
induce contact stresses between the mating teeth,
causing their wear and deformation and generating
intertooth clearances. This results in internal leakages in the machine, a decrease in working
pressure, and a lowering of volumetric efficiency.
The first serious strength analyses of gerotor
elements were carried out by Colburne [14], who
J. Strain Analysis Vol. 45

examined the influence of gear profile on intertooth

contact stress. Strength analysis of trochoidal gears
in pumps, carried out by the finite element method
(FEM) by Gomez-Montero et al. [15] showed that the
maximum stresses occur in the tooth pair moving
around the central point of the toothing. FEM
research into the strength of epitrochoids working
with orbital motion was carried out by Nag et al.
[16]. They proved that the deformations of particular
teeth assume various values and enable flow through
the intertooth channels of the machine.
The research outlined above has not exhausted the
topic, however. In particular, the question as to the
source of gear deformations, and consequently
clearances in the pump, remains unanswered.
Knowledge of the profile and size of clearances can
be used for improvement of the hydraulic pumps
mentioned above [10, 11], and ultimately for their
technological development. It is particularly important in the case of plastic gears, which are less
durable than steel gears [17]. The application of
plastics is advantageous for design reasons, because
gerotor pumps can work with ecological fluids and
generate a lot less noise. It is also advantageous for
technological and economic reasons, because plastic
gears can be manufactured by means of the simple
and cheap injection moulding method.
Thus, the following specific aims were formulated:
(a) determination, by means of FEM, of the
mechanism by which stresses and deformations
occur in the plastic cycloidal gear set used in
gerotor pumps;
(b) determination of the load range for the plastic
cycloidal gears, depending on the stress and
acceptable deformations.
For these purposes it was necessary to:
(a) analyse the design and operating principle of the
gerotor pump, as well as of the gear set working
within it;
(b) develop the fundamentals of the geometry and
kinematics, and specify the load distribution for
the gears;
(c) develop a model of the gear set;
(d) carry out a strength analysis of the model by
means of FEM.

DESIGN AND OPERATING PRINCIPLE OF THE

GEROTOR PUMP

The design of the gerotor pump according to

Stryczek [4, 12] is shown in Fig. 1. The main body
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Analysis of stress and deformation in plastic gears

Fig. 1

Design and operating principle of the gerotor pump: 1, 2, 3 body plates; 4, 5 cycloidal
gears; 6 bearing; 7 shaft; TCR internal tooth chamber; ICL input channel; ICR
input chamber; OCL output channel; OCR output chamber; LPZ low-pressure zone;
HPZ high-pressure zone; LHB lowhigh bridge; HLB highlow bridge; LHPZ low
high pressure zone; HLPZ highlow pressure zone

of the pump consists of three plates: the front plate

1, the central plate 2, and the back plate 3. In the
central plate 2 there is a gear set, 4 and 5, which is
driven by a shaft 7 located in bearings 6. Between the
internal toothing cycloids with the tooth difference
z2 2 z1 5 1, intertooth displacement chambers are
formed (TCR). In the back plate on the input side (I),
a cylindrical input channel (ICL) and a kidneyshaped input chamber (ICR) are formed, whereas on
the output side (O), an output channel (OCL) and an
output chamber (OCR) of the same shape are
formed. The input chamber is separated from the
output chamber by bridges (LHB and HLB).
The operating principle of the pump is as follows.
The working fluid enters the pump via the input port
(ICL) and fills the input chambers (ICR). Simultaneously, the intertooth displacement chambers
(TCR) move, increasing their volume and sucking
in the working fluid. Next, the intertooth displacement chambers (TCR) move on to the bridge (LHB)
where the suction process ends and the delivery
process begins. Successive intertooth displacement
chambers (TCR) move along the output chamber
(OCR), decreasing their volume and delivering the
working fluid. The working fluid flows out of the
pump through the output chamber (OCR) and the
output channel (OCL). Finally, the intertooth chambers move on to the bridge (HLB) where the delivery
process ends and the suction process begins.
The torque essential for revolution of the gears
and for realization of the delivery process is
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467

determined, according to Stryczek [4], by

M~

q
p
2p

In the process of delivery, the working fluid

remains at pressure p. It also flows on to the front
area within axial clearance ha .
As shown in Fig. 1, it is possible to distinguish four
zones in the pump, through which the displacement
chambers (TCR) move:
(a) the low-pressure zone (LPZ) determined by the
input chamber (ICR), with input pressure pi ;
(b) the zone of pressure increase (LHPZ) determined by bridge LHB, where the pressure rises
from pi to po ;
(c) the high-pressure zone (HPZ) determined by
the output zone (OCR), with pressure po ;
(d) the zone of pressure decrease (HLPZ) determined by bridge HLB, where the pressure falls
from po to pi .
The conclusion that can be drawn from the above
description is that the gear set in the gerotor pump
remains under combined mechanical and hydraulic
load. The mechanical load is generated by torque M
driving the gear set. The hydraulic load is caused by
the activity of the pressure p of the working fluid in the
intertooth displacement chambers, and also by the
activity of pressure p on the front surfaces of the
mating gears. These combined loads cause gear deforJ. Strain Analysis Vol. 45

468

K Biernacki and J Stryczek

mation, as well as an increase in intertooth clearances,

namely the radial clearance hr and the axial clearance
ha between the gear front and the pump body.
In order to achieve the aim of this paper, that is, to
specify the mechanism by which deformations occur
and to determine the load range for the gear set, it is
necessary first to specify precisely its geometry,
kinematics, and load distribution.

Fig. 2

3.1

GEOMETRY, KINEMATICS, AND LOAD

DISTRIBUTION OF THE GEAR SET IN THE
GEROTOR PUMP
Geometry

Figure 2 illustrates the method for designing the

epicycloidal gear set used in gerotor pumps according to Stryczek [47].

Designing the epicycloidal gear set: (a) designing the epicycloidal tooth; (b) designing the
epicycloidal gear set; (c) correcting and modifying the epicycloidal gear set

J. Strain Analysis Vol. 45

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Analysis of stress and deformation in plastic gears

Using the external toothing gear and tooth

number z1 , the internal toothing gear and tooth
number z2 5 z1 + 1 is designed (Fig. 2(b), shown in
blue). In this arrangement, the external toothing gear
with centre O1 turns around fixed centre O2, making
a family of shortened epicycloids. To this family, the
external envelope is drawn, which makes the toothing of the internal gear.
According to Stryczek [4], the equations used for
determining the profiles of the successive shortened
epicycloid making the family have the following
form

m
z1 g{c
l cos czz1 z1 cos
xef2 ~
2
z1

z1 z1z1 g{c
{l cos
z1

m
z1 g{c
l sin czz1 z1 cos
yef2 ~
2
z1

z1 z1z1 g{c
{l sin
z1

m
z1 z1 sin g{l sin z1 z1g
2
3
3

sin g{l sin z1 z1g7

{n q 5
1zl2 {2l cos z1 g
5

while the equation of the envelope for the shortened

epicycloid family according to Stryczek [4] is


z1 g{c{c
z1 g{c{c
sin z1 g{l sin z1 gz
z sin
z1
z1
4

As can be seen in Fig. 2(b), equations (3) are used

to design particular shortened epicycloids that make
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m
z1 z1 cos g{l cos z1 z1g
2
3
cos g{l cos z1 z1g7
{n q 5
1zl2 {2l cos z1 g

yeke ~

~0

xeke ~

7
5

m
z1 z1 cos g{l cos z1 z1g
2
m
ye1 ~ z1 z1 sin g{l sin z1 z1g
2
xe1 ~

a family. Equation (4), considering the position of

the particular epicycloids (angle c) is used to
determine the point that is an element of the
envelope in a given epicycloid (angle g). System of
equations (3), (4) has an implicit form, but it can be
solved by means of computer.
Figure 2(b) shows that both the external and the
internal gears feature disproportionate gearing.
Meshing of the convex teeth of the external gear
with the sharply ended teeth of the internal gear is
not good owing to considerable intertooth thrust and
wear. The teeth of both gears are also difficult to
manufacture.
Thus, in the third design step it was necessary to
introduce corrections and modifications of the tooth
profile. As depicted in Fig. 2(c), the correction of the
teeth is made without a change in distance of the
O1O2 axis. The correction is made by shifting the
profile of both gears towards the inside of the gear
set in section g. As a consequence, the external
toothing gear has a profile made by the internal
equidistance to the shortened epicycloid. On the
basis of Stryczek [4], the profile (shown in red) is
derived by means of the following equations (in the
equations, the correction coefficient v 5 g=r is
introduced)
7
5

The first step in the design process is to assume

the tooth profile. As shown in Fig. 2(a), the profile is
determined by the arc of the shortened epicycloid,
which is made by point M connected to the circle of
radius r rolling slidelessly on the outer side of the
fixed circle of radius rb .
The second step is to make the internal gear
element. It is made by the successive arc/tooth
number z1 , formed in a closed shortened epicycloid
(Fig. 2(b), shown in red). On the basis of Stryczek [4],
the following equations are adopted for the shortened epicycloid forming the tooth profile

469

The internal toothing gear, however, should have a

profile made by the equidistance to the envelope.
Nevertheless, the complex profile is replaced with
r 5 g arcs drawn from the vertices of the envelope.
The arcs are connected by arcs of the circle drawn
from the centre of circle O2. The modified profile of
the circle is shown in blue.
The epicycloidal gear set finally achieved, featuring the corrected and modified toothing (Fig. 2(c)), is
the most frequently applied system in hydraulic
machines such as gerotor pumps, orbital motors,
and control systems.
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470

3.2

K Biernacki and J Stryczek

Kinematics

Figure 3 illustrates the kinematic analysis of the

cycloidal gear set used in the gerotor pump.
It can be seen in Fig. 3(a) that all teeth, 19, 29, ,
69, of the external (active) toothing gear (shown in
red) mesh with teeth 10, 20, , 70 of the internal
(passive) toothing gear (shown in blue), making
contact points A1, A2, A3, , A7, which are arranged

in the contact line of the conchoidal profile (shown

in green). The contact lines can be divided by
vertical symmetry axis O1O2 into the active part
(the green continuous line) and the passive part (the
green dashed line). In the active part, the teeth of the
external (active) gear transmit the torque on to the
teeth of the internal (passive) gear, whereas in the
passive part the teeth slide on one another without
transmitting the torque. It is then necessary to
determine the contact ratio e, which, according to
the definition given by Stryczek [4], equals the
relation of the arc of action to the circular pitch. As
shown in Fig. 3, the arc of action is arc BD made on
the pitch circle with radius rw1 . The pitch circle rw1
must turn by this arc while one pair of teeth mesh
(1910), beginning from the engagement at point A1
to the disengagement at point A1k. Also, on the pitch
circle rw1 the gear circular pitch pw 5 BE is marked.
Hence, the contact ratio has the form
e~

BD
pw

where BD~prw1 =z1 zprw1 is the arc of the mesh

and pw ~2prw1 =z1 is the circular pitch.
The result of the above is the formula for the
contact ratio
e~

z1 z1
2

which establishes the fact that the value of the

contact ratio is greater than 1 and is far greater than
the value of the contact ratio for involute gearing.
Kinematic analysis has been carried out for the
rotation of the external gear by one pitch, namely by
angle a 5 2p=z1 .
Three characteristic positions of the external gear
have been specified:
(a) the initial position (Fig. 3(a)), when tooth 19 of
the external gear engages and is turned in
relation to gearing axis O 1 O 2 by angle
a 5 {p=z1 ;
(b) the central position (Fig. 3(b)), when tooth 19 of
the external gear is in gearing axis O1O2, namely
a 5 {p=z1 ;
(c) the final position (Fig. 3(c)), when tooth 19 of
the external gear remains turned in relation to
gearing axis O1O2 by angle a 5 zp=z1 .
Fig. 3

Kinematics of the cycloidal gear set: (a) initial

position of the external gear a 5 {p=z1 ; (b)
central position of the external gear a 5 0; (c)
final position of the external gear a 5 zp=z1

J. Strain Analysis Vol. 45

In the initial position, tooth pair 1910 engages at

point A1. At the same time, in the gearing on the
active part of the contact line, tooth pairs 2920, 39
30, and 4940 mate at points A1, A2, A3, and A4. On the
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Analysis of stress and deformation in plastic gears

471

passive part of the contact line, tooth pairs 5950, 69

60, and 1970 slide at points A5, A6, and A7.
In the central position, tooth pairs 1910, 2920, and
3930 at points A1, A2, and A3 shift on the active part
of the contact line. The tooth pair 4940, however,
disengages at point A4 and goes onto the passive part
of the contact line. On the passive part there remain
the tooth pairs 5950, 6960, and 1970 which come
into contact at points A5, A5, and A7.
In the final position, another tooth pair 6970
engages, and contact point A7 replaces point A1.

3.3

Load distribution of the gear set

What stems from the geometric and kinematic

analysis is that, while rotating, the teeth of both
gears remain in permanent contact, providing tightness of the displacement chambers. At the same
time, the chambers initially decrease and then
increase their volume, which results in the pumping
process. The intertooth displacement chambers
change their position in relation to the characteristic
zones of the pump defined in Fig. 1, which results in
a change in the mechanical and hydraulic load
distribution.
The mechanical and hydraulic load analysis,
similarly to the kinematic analysis, was carried out
for three characteristic positions of the internal and
external toothing gears with symmetry axis O1O2,,
namely the initial, the central, and the final positions
(Fig. 4). In the initial position (a 5 {p=z1 ) shown in
Fig. 4(a), the gear set is worked on by torque M
which generates the intertooth forces P2 {P2 ,
P3 {P3 , and P4 {P4 in tooth pairs 2920, 3930, and
4940 located in the active part of the contact line.
In pair 1910 there are no intertooth forces because
the teeth engage and the profiles slide against each
other. Neither do intertooth forces occur in the other
tooth pairs located on the passive part of the contact
line. At the same time, the intertooth displacement
chambers are worked on by the pressure of the
working fluid. The chambers located in the lowworking-pressure zone (LPZ) are worked on by the
input pressure pi , whereas the chambers located in
the high-pressure zone (HPZ) are worked on by the
output pressure po . The chamber located in the zone
of pressure increase (LHPZ) is also under the
influence of pressure, the value of which is equal
to the value of the output pressure po because it is
assumed that the chamber is connected by the axial
clearance ha and radial clearances hr to the highpressure zone (HPZ).
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Fig. 4

Load distribution of the cycloidal gear set: (a)

initial position of the external gear a 5 {p=z1 ;
(b) central position of the external gear a 5 0;
(c) final position of the external gear a 5 zp=z1

Similarly, the chamber that remains in the zone of

pressure decrease (HLPZ) is influenced by high
pressure po . Simultaneously, the working fluid at
high pressure po works on the front surface of the
gears. Finally, the broken line C, O1, O2, 4940
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472

K Biernacki and J Stryczek

separates the intertooth displacement chambers and

the front surfaces of the gears remaining under the
influence of input (low) pressure pi and output
(high) pressure po .
In the central position (a 5 0) shown in Fig. 4(b),
intertooth forces P1 {P1 occur in tooth pair 1910,
which engage, as well as forces P2 {P2 and P3 {P3
between tooth pairs 2920 and 3930, which are
already in the mesh. In tooth pair 4940, the forces
vanish, because the teeth go out of the active contact
line. Similarly, the intertooth forces do not occur in
the other tooth pairs located in the passive part of
the contact line. In the central position, the load
distribution generated by the pressure of the working fluid changes. The chambers located in the lowpressure zone (LPZ) and on the border with the
pressure increase zone (LHPZ) and the pressure
decrease zone (HLPZ) are influenced by low pressure
pi , while the chambers in the high-pressure zone
(HPZ) and on the border with the pressure increase
zone (LHPZ) and the pressure decrease zone (LPZ)
are influenced by high pressure po . At the same time,
the working fluid at output pressure po works on the
front surface of the gears. The vertical line C, O1, O2,
49-40 separates the intertooth displacement chambers and the front surface, which remain under the
influence of input (low) pressure pi and output
(high) pressure po (shown in red).
In the final position (a 5 zp=z1 ) shown in
Fig. 4(c), another tooth pair 6970 engages and
replaces tooth pair 1910. The intertooth forces and
load distribution that are generated by the pressure
of the working fluid are the same as those in the
initial position. The only difference is the change in
the position of the key through which torque M is
transmitted.
From the analysis carried out it can be concluded
that the mechanical and hydraulic load distribution
of the gear set in the gerotor pump changes
according to the angle of rotation. Therefore, a
complex state of stresses and deformations can be
anticipated, and the best method of studying the
problem is the finite element method (FEM).

4.1

COMPUTABLE MODEL OF THE CYCLOIDAL

GEAR SET
Geometric model, loads, and fixings

On the basis of the diagram of the gerotor pump

shown in Fig. 1, a geometric model of the cycloidal
gear set was prepared (Fig. 5). The parameter values
of the epicycloid listed in Table 1 were adopted.
J. Strain Analysis Vol. 45

The toothing profile of the external gear was

determined from equation (5). The toothing of the
internal gear was shaped in the form of arcs of a
circle drawn from the vertices of the envelope
circumscribed by equations (3) and (4). The geometric model is influenced by the mechanical load
resulting from the transmission of torque M by the
driver shaft of diameter d1 5 25 mm on to the key
situated in the external toothing gear and on to the
internal toothing gear. The hydraulic load of the
model stems from the impact of pressure p of the
working fluid located in the intertooth displacement
chambers of the gear set. The gear set remains in a
state of balance because, in accordance with formula
(1), torque M on the shaft will be equal to the torque
generated by pressure p.
The external gear toothing profile is derived from
equation (5). The internal gear toothing profile is
made according to the arc of the circle drawn from
the vertices of the envelope described by equations
(3) and (4).
The model must be fixed, and the way of fixing
also stems from the operating principle of the
gerotor pump shown in Fig. 1. It can be seen in the
figure that the external toothing gear is set on the
shaft 7 and can only revolve around axis O1. In the
model presented in Fig. 5(a), the gear is fixed radially
on the shaft of diameter d1 5 25 mm and can revolve
around axis Z. The internal toothing gear depicted in
Fig. 1 is located in the port of the central body 2 and
can revolve around axis O2. In the model presented
in Fig. 5(a), the gear is fixed radially on diameter
d2 5 75 mm, but it can revolve around axis Z.
As shown in Fig. 1, the gear set is also worked on
by pressure p of the working fluid in axial clearance
ha made between elements 2 and 3 of the body. This
presses the gear set to the body 1. On account of this,
in the model shown in Fig. 5(a), the end face of the
gear set is loaded with pressure p, while the opposite
face is fixed.

4.2

Finite element grid

The numerical model of the cycloid gear set was

made by means of the ABAQUS system version 6.7-5.
The license number 05UWROCLAW of the program
was leased by Wrocawskie Centrum SieciowoSuperkomputerowe at Wroclaw University of Technology, Poland.
The finite element grid shown in Fig. 5(b) was
made by means of eight-node HEXA solid elements,
typically used for creating solid models. The finite
element grid for the gear set was made from ca
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Analysis of stress and deformation in plastic gears

Fig. 5

Model of the cycloidal gear set: (a) load distribution; (b) finite element grid
Table 1

Values of parameters for the epicycloidal gear

Number

Parameter

Symbol

Value

1
2
3
4
5
6
7
8
9

Number of teeth in the external toothing gear

Number of teeth in the internal toothing gear z2 5 z1 + 1
Pitch circle radius
Modulus m
Tooth depth coefficient
Tooth profile shift
Tooth profile shift coefficient, correction coefficient v 5 g=r
Radius of the arc of the internal gear teeth r 5 g
Face width

z1
z2
r
m
l
g
v
r
b

6
7
4.875
9.714 mm
0.777
11.1125 mm
2.288
11.1125 mm
10.4 mm

500 000 elements. Those elements made the profile

of the gear set on plane XY. In order to model the
thickness of the gear set, 15 layers of HEXA elements
were built. The layers were arranged ca every 0.7 mm
along axis OZ until a thickness of the gear set of
b 5 10.4 mm was achieved (Fig. 5(a)). The HEXA
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element is an eight-node cube. The number of

nodes indicates that it is the first-order element.
Each node of the HEXA element has three degrees of
freedom, and they are shifted in relation to axes X, Y,
and Z. In the anticipated loci, grid refinements were
made, which can be clearly seen in Fig. 5(b). The loci
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474

K Biernacki and J Stryczek

of the refinements are tooth contacts of the mating

gears on the suction side (the left side of the model
in Fig. 5(b)) and the area of the splineway in the
active gear. Smaller refinements were made at the
corners of the tooth bearing of the passive gear. The
grid of the external toothing active gear consists of a
greater number of elements because the authors
believe that it is more strenuous.
The system enabled modelling of the surface
contact by means of a special algorithm characteristic of the ABAQUS system. The contact was located
in the area of the tooth contact on the suction side of
the gear set (the left side of Figs 5(a) and (b)). The
friction factor m was selected considering the plastic
type and the conditions present in the area of
contact (e.g. high pressure). The value m 5 0.4 was
determined on the basis of research results [18].
The numerical model allowed very precise determination of stresses and deformations for the gear
set, and the discrete action error level does not
exceed 0.02 per cent for the deformations, and ca 1.3
per cent for the stresses.

4.3

Selection of the plastic

As the plastic for the matched gears, pure polyoxymethylene (POM) was chosen. It is characterized by
relatively high mechanical strength and low strain.
The material has low water absorption and good
processability. Compression strength testing of POM
was conducted, and the stressstrain diagram
sc 5 f e was obtained (Fig. 6). The figure shows
that, for deformations e 5 00.15, stress sc increases

in an approximately linear manner, and the range

can be described as elastic. For deformations
e . 0.15, however, the stress sc changes according
to a parabolic law, and this is described as the plastic
stress range. In this case, the stress sc 5 80 MPa
corresponding to the deformation e 5 0.15, which
separates the elastic range from the plastic range, is
assumed to be the plasticity limit Re for POM.
For further stress analysis it was decided that the
compressive stress sc 5 Re 5 80 MPa would stand for
the maximum acceptable stress for the gear set, and
the reduced stress sz specified in FEM would be
compared with it.
4.4

Research programme

Research on the stresses and deformations in the

plastic cycloidal gear set was carried out for two
characteristic load states resulting from the operating principle of the machine (Fig. 1), as well as from
the assumed model (Fig. 5(a)). These are:
(a) the state of total mechanical and hydraulic load,
where torque M works on the mesh and
pressure p works on the intertooth displacement chambers;
(b) the state of partial hydraulic load, where
pressure p works on the face end of the gear set.
In both load states, research on the stresses and
deformations was conducted for three characteristic
positions of the gears, for which a prior theoretical
analysis of kinematics (Fig. 3) and load distribution
(Fig. 4) had been carried out.

Fig. 6 Stressstrain diagram for polyoxymethylene (POM)

J. Strain Analysis Vol. 45

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Analysis of stress and deformation in plastic gears

In the research process, the model was loaded

successively with torque M 5 7.16, 14.32, 17.9, and
21.48 N m, derived from formula (1), and pressure
p 5 4, 8, 10, and 12 MPa. The assumed displacement
of the gerotor pump was q 5 11.24 cm3/rev.

Fig. 7

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475

RESULTS AND DISCUSSION

Figure 7 depicts example results on the model of the

cycloidal gear set loaded with the total load resulting
from the activity of torque M 5 7.16 N m and pres-

The state of stresses and deformations in plane XY of the model of cycloidal gears for its
different positions. The pressure load of the model p54MPa and the torque load M57.16
Nm: (a), (b) initial position of the external gear a 5 {p=z1 ; (c), (d) central position of the
external gear a 5 0; (e), (f) final position of the external gear a 5 zp=z1
J. Strain Analysis Vol. 45

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K Biernacki and J Stryczek

sure p 5 4 MPa. The distribution of stresses and

deformations for the gear set in three characteristic
positions is presented. In order better to compare
the deformations, the deformed profile (in colour) is
shown against the background of the undeformed
gear profile (continuous black line).
The state of stresses and deformations for the
initial position of the external toothing gear
(a 5 {p=z1 ) is presented in Figs 7(a) and (b) respectively. Figure 7(a) shows that, in successive tooth
pairs 1910, 2920, and 39-30, stresses (intertooth
forces) occur, whereas in pairs 4940, 5950, 6960,
and 1970 no stresses (intertooth forces) occur.
The highest stress can be observed at the bottom
of tooth 19, where the activity of the splineway can
also be seen. In this area, the so-called stress bridge
is formed, and this bridge is the most strenuous spot
in the whole gear set. The reduced stress equals
sz 5 33.17 MPa and is lower than the maximum
acceptable stress sc 5 80 MPa assumed in section
4.3.
The state of the stresses can be explained by
analysing the state of deformations shown in
Fig. 7(b). In the figure it can be seen that the external
toothing gear deforms towards the active part of the
mesh, whereas the internal toothing gear deforms
towards the passive part of the mesh.
This causes mutual pressing of teeth 1910, 2920,
and 3930 and the formation of stresses (forces)
between them. At the same time, teeth in pairs 4940,
5950, 6960, and 1970 disengage, making radial
clearances hr . The greatest clearances are formed
between teeth 4940 and 5950. The maximum value
of the clearance recorded in pair 4940 in this
position equals hr 5 0.065 mm.
The state of stresses and deformations for the
central position of the external gear (a 5 0) is
presented in Figs 7(c) and (d) respectively. Figure 7(c) shows how, in the successive tooth pairs
1910, 2920, and 3930, gradually diminishing stresses
(intertooth forces) occur, while between teeth 4940,
5950, 6960, and 1970 stresses are not induced. The
maximum stress does not occur on the contact of the
teeth, as previously, but on the left side of the
splineway at the point where torque M is imposed.
The stress is sz 5 26 MPa and is also lower than the
acceptable stress sc 5 80 MPa.
It can be concluded from analysis of Fig. 7(d) that,
under the influence of the pressure, both gears are
moved in opposite directions and deformed, the
effect of which is that, between teeth 4940, 5950, 69
60, and 1970, radial clearances hr are formed. The
greatest clearances are made between teeth 4940
J. Strain Analysis Vol. 45

and 5950. The value of clearance hr , generated as a

consequence of deformations, equals hr 5 0.082 mm
and is the highest at this position.
Finally, the state of stresses and deformations for
the final position of the external toothing gear
(a 5 zp=4) is presented in Figs 7(e) and (f) respectively. In terms of quality, the obtained states of
stresses are similar to those obtained for the initial
position of the external gear (Figs 7(a) and (b)). In
tooth pairs 6970, 1910, and 2920 gradually decreasing stresses (forces) are induced, while between the
teeth 3930, 4940, 5950, and 6960 radial clearances hr
are formed.
The highest stress is induced on the left side of the
splineway, at the spot where torque M is imposed,
and amounts to 25 MPa. The maximum value of the
radial clearance in tooth pair 3930 amounts to
hr 5 0.037 mm.
The stress and deformations of the cycloidal gear
set put under partial load, i.e. pressure p 5 4MPa
affecting the end face of the gear set, were also
studied (Fig. 5(a)). The achieved stress was
sz 5 4 MPa, which is of course lower than the
maximum acceptable stress sc 5 80 MPa. The maximum axial clearance generated by the moving gear
set is ha 5 0.018 mm, which is far lower than the
maximum radial clearance hr 5 0.082 mm.
Next, strength analysis of the gear set for the
successive load values determined by torque M and
pressure p assumed in the research was carried out.
It was observed that, for loads M 5 17.82 N m and
p 5 10 MPa, the reduced stress sz induced in the
gears shows values close to the acceptable for POM,
namely sc 5 80 MPa. Higher loads might cause
plastic deformation of the gears.
Deformation analysis was also conducted, and
characteristics of radial clearance hr and axial
clearance ha were developed, depending on the
pressure p working on the gear set. Figure 8 shows
that the clearance increase is directly proportional to
the increase in pressure p of the working fluid
working on the gear set.
For the boundary pressure working on the gear set,
p 5 10 MPa, the clearances are hr 5 0.0204 mm and
ha 5 0.046 mm. These values are higher than the
boundary values hr max 5 0.1 mm and ha max 5
0.03 mm assumed for the gerotor pumps in earlier
studies [10, 11]. Ultimately, on the basis of the
characteristics presented in Fig. 8, it can be stated
that the plastic gear set should not be loaded with a
pressure higher than 5 MPa.
Figure 9 compares theoretical analyses carried out
on the cycloidal gear set made of undeformable
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Analysis of stress and deformation in plastic gears

Fig. 8

Dependency diagram between the clearances in the cycloidal gear set and the working
pressure p imposing a load on the gears: (a) change diagram of the radial clearances
(maximal and minimal) hr 5 f p; (b) change diagram of the axial clearances ha 5 f p

Fig. 9

Comparison of the geometry, kinematics, and force (of stresses) in the cycloidal gear set:
(a) undeformable material; (b) deformable material POM

material with computer analyses conducted by

means of FEM for the gear set made of deformable
POM.
Analysing the geometry of the gear set made of
undeformable material (Fig. 9(a)), it can be ascertained that the gears keep their theoretical shape
based on equations (5), and the teeth of the external
gear contact the teeth of the internal gear.
The gear set made up of deformable plastic POM
(Fig. 9(b)) undergoes deformation. The external gear
teeth undergo deformation and are moved in the
direction of the active part of the meshing, while the
internal gear teeth are moved in the direction of the
passive part. This is illustrated in Fig. 9(b) by brown
arrows. As a result of deformation in the area of the
lower bridge on the passive side, intertooth radial
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477

clearances hr are formed. The higher the pressure of

the working medium p, the greater is the strain and
the larger are the radial clearances hr (Fig. 8(a)). By
considering the shape of the gear set of deformable
material POM in the plane perpendicular to the end
face, it is ascertained that it is pressed and its width
decreases in relation to its initial value.
Analysing the kinematics of the gear set made of
undeformable material (Fig. 9(a)), it can be ascertained that the contact line has the shape of a
conchoid that is divided by the axis of symmetry
O1O2 into the active part (continuous line) and the
passive part (broken line). Because of this, the tooth
pair engages at point C and disengages at point A1k.
In the case of gears made of POM (Fig. 9b), the
contact line is also a conchoid, but, as a result of
J. Strain Analysis Vol. 45

478

K Biernacki and J Stryczek

tooth deformation and the formation of intertooth

clearances hr , the pair engages at point C9 before
point C and disengages at point D9, which is situated
ca 1 pitch before point A1k.
The arc of the active part of the contact line and
the contact ratio e decrease. Using equation (6), the
dependency on the actual contact ratio is determined
er ~

z1 {1
2

The values of the actual contact ratio er evaluated

from equation (8) are smaller than the theoretical values
of the contact ratio e evaluated from equation (7).
Analysis of the system of forces and loads of the
gear set made of undeformable material (Fig. 9(a))
established that the intermediate forces P2 {P2 ,
P3 {P3 , and P4 {P4 have an influence only in the
active part of the meshing CA1k in its entire range.
The directions of action and the values of the
intermediate forces change, and therefore variable
stresses in these teeth should be expected. The
forces and stresses are difficult to determine analytically.
In the gear set made of undeformable plastic
(Fig. 9(b)), the intertooth forces P1 {P1 , P2 {P2 , and
P3 {P3 are also active in the active part of the
meshing C9D9, which is, after all, smaller than part
CA1k because of the deformation. The directions of
the forces change in the course of the gear revolution.
The values of the forces (stresses) present in individual tooth pairs 1910, 2920, and 3930 decrease. It can
be stated that the ratio of the force values in the
following tooth pairs is P1 : P2 : P3 5 1:2/3:1/3.

CONCLUSIONS

The aims formulated at the beginning of the work

have been achieved.
Using the finite element method and the ABAQUS
package, the mechanism of generation of stresses
and deformations in the plastic cycloidal gear set of
gerotor pumps has been described. It has been
observed that there are two parts in the mesh: the
active part, where intertooth forces are induced
between the teeth of the internal and the external
gear, and the passive part, where intertooth forces do
not occur. The division line runs approximately
along axis O1O2 which connects the centres of gear
revolution. The intertooth forces and stresses have
various values. The most important forces and
J. Strain Analysis Vol. 45

stresses are induced in the first tooth pair, which

engage in the area of the mesh C pole. In successive
mating tooth pairs, the forces and stresses gradually
decrease (Fig. 7).
A characteristic of the deformations in the gear set
is that the external gear teeth are deformed and
moved towards the active part of the mesh, whereas
the internal gear teeth are deformed and moved
towards the passive part. Thus, intertooth radial
clearances hr are made, and their highest values are
achieved between the tooth pairs located in the zone
of pressure increase and the high-pressure zone
(Fig. 9).
A way of determining the loadability of the plastic
cycloidal gear set used in gerotor pumps has been
specified. It has been concluded that stress and
deformation analysis must be carried out together.
It must be ensured that reduced stresses sz in the
gears are not higher than the acceptable stresses,
which in this case are compressive stresses sc equal
to the plasticity limit Re of POM, namely sc 5 Re.
This is formulated as
sz sc ~Re
At the same time, it has to be made sure that the
deformations of the teeth and gears, as well as the
radial clearances hr and axial clearances ha resulting
from them, are smaller than the extreme clearances
hr max and ha max assumed for the particular size of
gerotor pump. This is formulated as
hr vhr max ,

ha vha max

From the viewpoint of hydraulics, the condition of

deformations is more important than the condition
of stresses. This is so because, by keeping the
stresses lower than the acceptable (sz , sc ), it is at
the same time possible to achieve deformations and
clearances greater than the extreme (hr . hr max ,
ha . ha max ), which causes flaws in the pumping
process, as well as lowering of the working pressure
and pump efficiency. In general, the gear deformations can be reduced in two ways:
(a) by applying a higher-strength plastic, i.e. a
plastic with higher acceptable stresses sc 5 Re;
(b) by modifying the cycloidal gear set design.
Finally, knowledge of the deformation mechanism
in plastic cycloidal gears, and resultant knowledge of
the profile and size of the internal clearances in the
pump, can be used for designing high-precision
hydraulic models of the pump, and for improving its
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Analysis of stress and deformation in plastic gears

design and at the same time its technical parameters.

F Authors 2010
REFERENCES
1 Pippenger, J. J. and Dong, J. X. History of gerotor
hydraulics. SAE Off-Highway Engng, June 2004, pp.
4045.
2 Sannikow, V. Planetarnye reduktory s vnecentroidnym cevocnym zacepleniem. Masgiz, 1948 (Moscow).
3 Colbourne, J. R. The geometry of trochoid envelopes and their application in rotary pumps.
Mechanism and Mach. Theory J., 1974, 9, 421435.
4 Stryczek, J. Koa zebate maszyn hydraulicznych.
Oficyna Wydawnicza Politechniki Wrocawskiej,
Wrocaw, 2007, available from http://www.dbc.
wroc.pl/dlibra/docmetadata?id520045&from5
&dirids51.
5 Stryczek, J. Cycloidal gears in design of gear
pumps and motors. Arch. Mach. Des., 1990, (12),
5788.
6 Stryczek, J. Principles of the design of cycloidal gears
in hydraulic machinery. Arch. Mach. Des., 1990, (3),
201218.
7 Stryczek, J. Gerotor und Orbitmaschinen. Projektierungsgrundlagen. Oelhydraulik und Pneumatik,
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ller, K. Die Ring-Rotor-Pumpe ein ger8 Scho
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Pneumatik, 1974, (5), 396398.
sthof, P. and Schneider, J. Grundlagen der
9 Wu
Planetmotoren Vorstellung eines neuen Planet ilhydraulik und Pneumatik, 1981, (2),
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FPNJ PhD Symposium, Barcelona, Spain, 2004,
225236.
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Achen, Germany, 2006.
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` , S., Nervegna, N., Rundo, M., and Margaria,
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Conference (3rd JFK), Achen, Germany, 2002, 153
167.

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14 Colbourne, J. R. Reduction of the contact stress in

internal gear pumps. Trans. ASME, J. Engng for
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APPENDIX
Notation
g
h
m
M
p 5 po 2 pi
pw
q
r
rb
rw1 , rw2
v 5 g=r
xe , ye
xef , yef
xeke , yeke
z1 , z2

a
c
e
g
l
r

equidistance shift
whole tooth depth
modulus
theoretical torque on the pump shaft
difference in output pressure po and
input pressure pi
circular pitch
pump displacement per shaft
revolution
radius of the arc of the internal gear
teeth
base circle radius
pitch circle radius
correction coefficient (Fig. 3(c))
epicycloid coordinates
epicycloid family coordinates
epicycloid equidistance coordinates
tooth number of the active gear and
passive gear respectively
rotation angle of the internal gear
eccentricity rotation angle
contact ratio
epicycloid angle
tooth depth ratio
generating circle radius

J. Strain Analysis Vol. 45