International Journal of Applied Engineering Research

ISSN 0973-4562 Volume 9, Number 22 (2014) pp. 13061-13071

© Research India Publications
http://www.ripublication.com

Stress Analysis and Effect of Misalignment in Spur Gear

1*
S Prabhakaran, 2D S Balaji and 3C Joel
1
*Associate Professor, Anand Institute of Higher Technology,
Chennai, Tamilnadu, India.
E-mail: prabhakaran.sk1980@gmail.com@gmail.com
2
*Assistant Professor, Anand Institute of Higher Technology,
Chennai, Tamilnadu, India.
E-mail: balajimailer@gmail.com
3
*Assistant Professor, Anand Institute of Higher Technology,
Chennai, Tamilnadu, India.
E-mail: joe_hce@yahoo.com

Abstract

Stress analysis has been a key area of research to minimize failure and
optimize design. The geometrical parameters, such as the face width and
module, are considered important for the variation of stresses in the design of
gears. Specifically, the face width is important for spur gears. Using modeling
software, 3-D models for different modules in spur gears are generated, and
the simulation was performed using ANSYS to estimate the bending and
contact stresses. The Lewis formula and Hertezian equation were used to
calculate the bending stress and contact stress, respectively. The results of the
theoretical stress values are compared with the stress values from the finite
element analysis.
The variation of the bending stress with various angular misalignments
parallel to the plane of action is performed for spur gear. Finite element
analysis for maximum bending stress is performed for parallel shafts and
compared it to the maximum bending stress for 1o, and 2o for spur gear.
The stress analysis through mesh sensitivity and effect of contact stress due to
geometry modification is done.

Keywords: Stress analysis, finite element model, Bending stress, Contact

stress.

Introduction
Gearing is one of the most effective methods for transmitting power from one shaft to

Paper Code: 27507 - IJAER

13062 S Prabhakaran et al

another with or without changing the speed. Spur gears are the most common type of
gears. Spur gears have straight teeth, are mounted on parallel shafts and are mainly
used to create very large gear reductions. The pressure angle is an important factor for
spur gears to prevent undercutting when the number of teeth is small and to adjust the
centre distance.
Modern mechanical design involves complicated shapes, which are sometimes
made of different materials that as a whole cannot be modeled by existing
mathematical tools. Engineers need the FEA to evaluate their design. A complex
problem is divided into smaller and simpler problems that can be solved using the
existing knowledge of the mechanics of materials and mathematical tools. The finite
element method can proficiently supply this information, but the generation of a
proper model is time consuming. Therefore, a pre-processor method that builds up the
geometry required for finite element analysis may be used to reduce the modeling
time, such as Pro/Engineer. Pro/Engineer can generate three-dimensional models of
gears. In Pro/Engineer, the generated model geometry is opened in ANSYS for
analysis. The application of finite element analysis allows the formation of bearing
contacts during the cycle of meshing to be investigated and a stress analysis to be
performed. The design of finite element models and the settings of boundary
conditions are automated[1].The theory of gearing and the modifications of the gear
geometry are necessary to improve the conditions of meshing [2]
The common problem in the rotating mechanisms is shaft misalignments.
Misalignment in the meshing gear results in uneven load distribution resulting in shift
of peak bending stress to the edge of face width. Misalignment in meshing alters the
location of contact on tooth flank and may lead to large stresses and increase noise of
gear pair. These Mesh misalignments can be classified in to three types
1. Parallel Misalignment
2. Angular Misalignment parallel to the plane of action
3. Angular Misalignment perpendicular to the plane of action

Input Parameters of Spur Gear of Material Steel 40Ni2Cr1Mo28

Table 1 Geometric Input Parameters for Spur Gear

Description Gear Pinion

Material Steel 40Ni 2Cr1Mo28 Steel 40Ni2Cr1Mo28
Number of teeth(Z) 63 18
Young’s Modulus(E) 2.10*105 N/mm2 2.10*105 N/mm2
Speed (N) 800 rpm 1500rpm
Power (P) 45KW 45 KW
Poisson Ratio 0.3 0.3
Normal Module (m) 2,3,4,5,6,7 mm 2,3,4,5,6,7 mm
Normal Pressure Angle 20o 20o
Stress Analysis and Effect of Misalignment in Spur Gear 13063

Table 2 Results Obtained for Different Modules of Spur Gear

Module(m)
Formula
Description 2 3 4 5 6 7
Used
Pitch Diameter
m*z1 36 54 72 90 108 126
(d) mm
Circular Pitch
πd1/Z1 6.28 9.42 12.57 15.71 18.85 21.9
(Pc) mm
Diameter Pitch
Z1/d1 0.5 0.33 0.25 0.2 0.17 0.14
(Pd) mm
Centre Distance m(Z1 + Z2)
81 121.5 162 202.5 243 283
(a) mm 2
Velocity factor
(6 + v)/6 1.47 1.71 1.94 2.178 2.41 2.64
Kv

Effect of Modules in Spur Gear

In spur gears, the bending stresses are calculated by varying the modules (3,4,5,6,7
and 8 mm) for a constant load as well as by keeping the other parameters, such as the
number of teeth, pressure angle and face width, constant.
F
σ = (1)
b∗m∗Y

Ft=6366N b=50mm m=5mm Y=0.3

σ = 84.88N/mm

Yj =0.5 K v=2.178 K o =1 Ks=0.7 Km =1.2

Ft
σ = (Kv ∗ Ko ∗ Ks ∗ (0.93Km) (2)
bm Y
σ = 86.65N/mm

The two-dimensional tooth profile and bending stress distribution plots for
module 5 with mesh in FEA are shown in figure 1 and 2, respectively. The desired
constraints and loads were applied. Similarly, figure 4 and 5 shows these parameters
for module 6. The contact stress distribution plots shown in figures 3 and 6 show a
maximum contact stress value of 559.4 N/mm2 for module 5 and 448.56 N/mm2 for
module 6.
13064 S Prabhakaran et al

Figure 1 Spur Gear Tooth Profile Figure 4 Spur Gear Tooth Profile
with Mesh for Module 5 with Mesh for Module 6

Figure 2 Bending Stress Distribution Figure 5 Bending Stress Distribution

Plots of Spur Gear for Module 5 Plots of Spur Gear for Module 6

Figure 3 Contact Stress Distribution Figure 6 Contact Stress Distribution

Plot of Spur Gear for Module 5 Plot of Spur Gear for Module 6

R1=rp1+sinα (3)
R2=rp2+sinα (4)
Stress Analysis and Effect of Misalignment in Spur Gear 13065

The Hertz equation for contact stresses in the teeth then takes the following
form:
K F 1 1
σ = −C ( + ) (5)
b cos α R R

1
C = (6)
1−v 1−v
π( E + E )

k C
σ =C Fk k k (7)
d bY
(Negative sign because σc is a compressive stress)

R1=45+sin20=45.342 mm R2=157.5+sin20=157.842 mm
From equation 5,6 & 7
Cp=191.645 σ = 555.7N/mm σ = 563.7 N/mm

Table 3 shows the comparison of the bending stress values calculated using the
Lewis equation, AGMA and ANSYS for different modules. The differences in the
bending stress values between the Lewis equation and ANSYS are tabulated. The
table clearly shows that the bending stress values obtained using all three methods are
very close to each other and well within the limit. Higher modules prepared for larger
power transmission values with minimum bending stress values.

Table 3 Comparison of Maximum Bending Stress Values for Different Module in

Spur Gear

S.No Module Bending stress Bending Bending Difference

(mm) value by Lewis stress value stress value [%]
formula by AGMA by ANSYS
(N/mm2) (N/mm2) (N/mm2)
1. 2 212.2 216.6 218.2 0.73
2. 3 141.47 144.4 146.25 1.26
3. 4 106.1 108.31 110.3 1.80
4. 5 84.88 86.65 88.87 2.4
5. 6 70.73 72.21 74.14 2.6
6. 7 60.63 61.89 63.24 2.13

Table 4 compares the contact stress values obtained using the Hertz approach,
AGMA and ANSYS for different modules. The values of the contact stress obtained
using the three methods decreases as the module increases. The contact stress values
obtained through all the three methods are close to each other.
13066 S Prabhakaran et al

Table 4 Comparison of Maximum Contact Stress Values for Different Module

in Spur Gear

S.No Module Contact stress Contact Contact Difference

(mm) value Hertz by stress value stress value [%]
Equation by AGMA by ANSYS
(N/mm2) (N/mm2) (N/mm2)
1. 2 1794 1831.4 1817.5 0.76
2. 3 1033 1052.3 1041 1.07
3. 4 731 743.5 737.5 0.81
4. 5 555.7 563.7 559.4 0.76
5. 6 444.5 451.5 448.56 0.65
6. 7 369.6 375.3 371.22 1.09

Influence of Shaft Misalignment on Spur Gear Tooth

The variation of the bending stress for spur gear with various angular misalignments
parallel to the plane of action is studied. FEA analysis for maximum bending stress is
performed for parallel shafts and compared it to the maximum bending stress for
angle 10, and 20.
The table 5 shows that the maximum bending stress increases with the increase
in angular misalignment and the load concentration is more on the edge of the gear
tooth as the angle increases.

Table 5 Maximum Bending Stress for Various Angular Alignments

Module-mm Angular Alignment Maximum Bending Stress N/mm2

2 Parallel 218.2
10 230.5
20 235.6
3 Parallel 146.25
10 155.31
20 158.61
4 Parallel 110.3
10 118.6
20 120.4
5 Parallel 88.87
10 90.58
20 91.24
6 Parallel 74.14
10 75.51
20 76.44
7 Parallel 63.24
10 65.40
20 66.12
Stress Analysis and Effect of Misalignment in Spur Gear 13067

Calculation of Stress Distribution Factor for spur gear

The load distribution factor can be calculated from the empirical method of AGMA
2001/2101.This method is recommended for normal, relatively stiff gear designs
which is defined as
K = 1.0 + C + C (8)

Where Cpf is Pinion Proportion factor and Cma is Mesh alignment factor. In the
present study the load distribution factor for parallel gear is defined as one and the
stress distribution factor for the various angular alignments can be calculated as
σ = K ∗σ ∗X (9)
σ
K =( ) (10)
σ ∗X

Where X is multiplication factor and Km is load distribution factor. Table 6

displays the obtained load distribution factors for various angular misalignments.

Table 6 Load Distribution factors for various Alignment

Module(mm) Angular Alignment load distribution factor

2 Parallel 1.00
10 1.06
20 1.08
3 Parallel 1.01
10 1.07
20 1.09
4 Parallel 1.01
10 1.09
20 1.1
5 Parallel 1.02
10 1.04
20 1.05
6 Parallel 1.03
10 1.04
20 1.06
7 Parallel 1.02
10 1.06
20 1.07

Contact Stress Analysis in 2D and 3D Model for spur Gear

The stress analysis through mesh sensitivity and effect of contact stress in Spur gear
due to misaligned assembly and geometry modification are studied. The static stress
analysis will be conducted in the 2D model and the 3D model respectively.
13068 S Prabhakaran et al

Mesh Sensitivity Analysis for spur gear

To achieve accurate stress values, mesh sensitivity analysis is conducted under 5
categories for each model ranging from 1340 nodes to 4756 nodes.

Table 7 Mesh Sensitivity Analysis for different categories

Category No. of Nodes No. of Nodes on Contact Stress in

Contact Pairs N/mm2
Category 1 1340 30 55.65
Category 2 1620 50 81.52
Category 3 4180 80 329.33
Category 4 4580 120 330.2
Category 5 4756 160 332.5

The table shows that the stresses do not appear to have converged even when
mesh density has reached 4756.

Stress Analysis in a Mesh Cycle for spur gear

To calculate the stress during a mesh cycle, gear angle θ is used to drive the gears
based on the gear assembly. Assume the gears rotate in the range from -10º to 10º
based on the mesh position at the pitch point of the static analysis. Based on the
calculation and the graphs the stress at every mesh position are analyzed and
identified in the mesh cycle. Three different categories have been analyzed in order to
investigate the effect of the misalignment and the geometry modification on the
contact stress. The categories are:
Category 1 The normal involute gears with accurate assembly.
Category 2 The normal involute gears with 0.1 deg shaft misalignment.
Category 3 The tooth profile modification in gear through tip relief.

The modifications of the gear tooth profile, through tip relief are one of the best
solution to improve the distribution of the contact stress due to shaft misalignment
and assembly deflection which result in very high localized contact. We have
analyzed the effect of tip relief on the contact stress.
Linear and parabolic curves are common for tooth profile modifications, as
shown in Figure 7. The tooth profile is modified in parabolic form.
Stress Analysis and Effect of Misalignment in Spur Gear 13069

Figure 7 Linear and parabolic form of the tip relief

Figure8 Maximum Figure9 Maximum Figure10 Maximum

Contact stress Contact stress Contact stress
distribution for Normal distribution for distribution for Gear
Gear Misaligned Gear with Tip Relief

90 Normal Model
85
80
75
70 0.1 Degree Misalignment
65
60
55
50 Tip Relief
45
40 (Max. Bending Stress values
35 N/mm2)
30
25
20
15
10
5
0
-10 -8 -6 -4 -2 0 2 4 6 8 10

Rotation Angle (deg)

Figure 11 Distribution of Stress among the three Categories

The figure 8 clearly shows damage occurs at the edge of tooth due to the high
concentrated contact in one side near the edge in the normal category. During shaft
13070 S Prabhakaran et al

misalignment, the stress concentration is intensive at the edge as shown in Figure

9.As shown in Figure 10, the contact stress occurs along the whole width of the tooth.
Contact stress area moves from one side toward the whole width of the tooth and the
contact stress is reduced due to the geometry modification. Figure 11 shows the
distribution of stress among the three categories. The graph shows that the peak
contact stress occurs in normal model and shaft misalignment when no tip relief is
used.
For a misaligned gear, the edge contact is much more serious than the normal
gear and has two peak maximum contact stress. Regarding the modified gear, the
applied tip relief avoids contact on edges and the corresponding stress peaks have
been eliminated.

Conclusion
In spur gears, the design of the teeth is purely based on bending and contact stresses.
The bending and contact stresses using AGMA for different modules in spur gears are
calculated. The stresses are also calculated for spur gears using the Lewis and Hertz
equations. The results obtained for the bending and contact stresses by AGMA, Lewis
and Hertz equations are validated using the FEA approach.
The variation of the bending stress with various angular misalignments parallel
to the plane of action is studied for spur gear and load concentration factor is
calculated.
Finite Element Analysis for maximum bending stress is performed for parallel
shafts to the plane of action and compared with the maximum bending stress for angle
10 and 20. The maximum bending stress increases with the increase in angular
misalignment and the load concentration is more on the edge of the gear tooth as the
angle increases.
To achieve accurate stress values, mesh sensitivity analysis is conducted under
five categories for each model ranging from 1340 nodes to 4756 nodes. The results
have shown that the stress does not appear to be converged even when mesh density
has reached 4756.
Three different categories have been analyzed for contact stress in order to
investigate the effect of misalignment and the geometry modification. The categories
are normal involute gears with accurate assembly, normal involute gears with 0.1
degree shaft misalignment and the tooth profile modification in gear through tip relief.
The results have shown that the damage occurs at the edge of one side of a tooth due
to the high concentrated contact in the normal category. In shaft misalignment, the
stress concentration is intensive at the edge. Contact stress area moves from one side
toward the whole width of the tooth and the contact stress is reduced due to the
geometry modification. The graph shows that the maximum contact stress occurs in
normal model and shaft misalignment, when no tip relief is used.
Stress Analysis and Effect of Misalignment in Spur Gear 13071

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13072 S Prabhakaran et al