CONTENTS

Sr.no Description Page no.

1 Abstract 1
2 Introduction 2
3 Literature Study 3
4 Objective 5
5 Methodology 6
6 Material Selection 8
7 Result and 9
Discussion
8 Conclusion 20
9 References 21
ABSTRACT
Gear is the one of the important machine element in the mechanical power transmission system.
Spur gear is most basic gear used to transmit power between parallel shafts. Spur gear generally
fails by bending failure or contact failure. This paper analyses the bending stresses
characteristics of an involute spur gear tooth under static loading conditions. The tooth profile
is generated using solidworks and the analysis is carried out by Finite element method using
ANSYS software. The stresses at the tooth root are evaluated analytically using existing
theoretical models. The theoretical and FEM results are compared. The results obtained
theoretically are in good agreement with those obtained from software. Also an attempt is made
to introduce Stress and displacement characteristics of tooth under dynamic loading conditions.
Key Terms- Spur gear design, Gear, Composite, analysis, dimension.
INTRODUCTION
In the today’s world of industrialization Gears are the major means for the mechanical power
transmission system, and in most industrial rotating machinery. Because of the high degree of
reliability and compactness gears dominates the field of mechanical power transmission.
Gearbox is used to convert the input provided by a prime mover into an output required by end
application. Due to increasing demand for quiet and long-term power transmission in machines,
vehicles, elevators and generators, people are looking for a more precise analysis method of
the gear systems. Spur gear is the most basic gear used to transmit power between two parallel
shafts with almost 99% efficiency. It requires the better analysis methods for designing highly
loaded spur gears for power transmission systems that are both strong and quiet. Due to
development of computers people are using numerical approach for the analysis Static and
Dynamic Analysis of Spur Gear . Also static as well as dynamic, both loading conditions of
gear can be easily analyzed in Ansys which is not the case with Analytical method.
LITERATURE STUDY

 S.Mahendran, K.M.Eazhil, L.Senthil Kumar [1] carried out DESIGN AND

ANALYSIS OF COMPOSITE SPUR GEAR. This project includes design of the spur
gear to study the weight reduction and stress distribution for cast steel and composite
materials. They designed the spur gear model using design software and studied the
impact analysis and torque loading for cast steel and composite materials. Finally, by
comparing and analyzing the composite gear with existing cast steel gear they
concluded that the stress induced, deformation and weight of the composite spur gear
is less as compared to the cast steel spur gear.
 V. Siva Prasad et al [2]. 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.

 Vivek Karaveer et al [3]. This paper presents the stress analysis of mating teeth of the
spur gear to find maximum contact stress in the gear tooth The results obtained from
finite element analysis are compared with theoretical Hertz equation values. The spur
gears are modeled and assembled in ANSYS DESIGN MODELER and stress analysis
of Spur gear tooth is done by the ANSYS 14.5 software. It was found that the results
from both Hertz equation and Finite Element Analysis are comparable. From the
deformation pattern of steel and grey cast iron, it could be concluded that difference
between the maximum values of steel and grey CI gear deformation is very less.
 Mahebub Vohra et al [4]. In this paper, Metallic material Cast iron and Non- Metallic
material Nylon are investigated. The stress analysis of the lathe machine headstock
gear box is analysed by finite element analysis. Analytical bending stress is calculated
by two formula Lewis formula and AGMA formula. Analytical results are compared
with the finite element method result for validation. This study concludes that, finite
element method software ANSYS have values of stress distribution were in good
agreement with the theoretical results. Besides non-metallic material can be used
instead of metallic material because non-metallic material provide extra benefits like
less cost, self-lubricating, low noise, low vibration and easy manufacturing.
 Utkarsh.M.Desail, Dhaval.A.Patel carried out MODELING AND STRESS
ANALYSIS OF COMPOSITE MATERIAL FOR SPUR GEAR UNDER STATIC
LOADING CONDITION. The objective of this project is to improve the performance
of gear by using alternate materials. Composite materials provide adequate strength
with weight reduction and they are emerging as a better alternative for replacing
metallic gears. In this work, a metallic gear of Alloy Steel is replaced by the composite
gear of 30% Glass filled Poly-Ether-Ether-Ketone(PEEK) to increase the working life
of the gears to improve overall performance of machine. Such composite materials
provide much improved mechanical properties such as better strength to weight ratio,
more hardness, and hence less chances of failure. In this project, the modeling of spur
gear is carried out using SOLIDWORKS and bending stress analysis of spur gear is
arried out using ANSYS V14.
OBJECTIVES
The objective of the project is to reduce the stress distribution, deformation and weight of spur
gear by using composite materials in the application of gear box. The designed composite spur
gear is compared with the existing gear materials, such as structural steel, gray cast iron and
aluminium alloy. The tool which is used to analyze the different spur gear materials is ANSYS.
In this, the analysis of torque loading and stress induced are to be performed for the materials
chosen. The final outputs of these analyses for all the materials are to be compared. From this
comparison, the stress induced, deformation and weight for composite spur gear materials are
to be less than that of the general spur gear materials.
METHODOLOGY
Model = TATA SUPER ACE

Engine = TATA475 TCIC BSIII)

The Spur Gear model is created using Solid works software. The model is shown below:
The solidworks model shown above is imported into Ansys workbench where it is where static
structural and modal analysis is conducted. The model is first meshed to fine sizing before the
total deformation and von misses stresses are calculated on application of 135Nm torque. This
is calculated for all the materials listed in the next section. Similarly, modal analysis is
conducted for each case at 10 modes in order to find the natural frequency of vibration. The
results are tabulated in the results and discussion section.
MATERIALS SELECTION:

1. Structural Steel:
Density = 7850 kg/m3
Young modulus = 200 GPa
Poisson’s ratio = 0.3
Ultimate Tensile Strength = 460 MPa
Yield Tensile Strength = 250 MPa
Bulk modulus = 166 GPa

2. Gray Cast Iron:

Density = 7200 kg/m3
Young modulus = 110 GPa
Poisson’s ratio = 0.28
Ultimate Tensile Strength = 430 MPa
Ultimate Compressive Strength = 820MPa
Yield Tensile Strength = 276 MPa
Bulk modulus = 83.3 GPa

3. Aluminium Alloy:
Density = 2770 kg/m3
Young modulus = 71 GPa
Poisson’s ratio = 0.33
Ultimate Tensile Strength = 310 MPa
Yield Tensile Strength = 280 MPa
Bulk modulus = 69.6 GPa

4. Epoxy E Glass UD:

Density = 2000 kg/m3
Young modulus = 450 GPa (X Direction)
= 100 GPa (Y& Z Directon)
Poisson’s ratio = 0.3 ( XY & XZ) = 0.4 (YZ)
Ultimate Tensile Strength = 1100 MPa ( X Direction) = 35 MPa ( Y&Z Direction)
RESULT AND DISCUSSION
Material Maximum Von Misses
Deformation(mm) Stress(MPa)
Aluminium alloy 0.01822 21.19
Grey Cast Iron 0.01189 21.665
Structural Steel 0.00651 21.49
Epoxy E glass UD 0.05185 25.167

A) STATIC ANALYSIS

Fig: Aluminium
Fig: Grey Cast Iron
Fig: Structural Steel
Fig: Epoxy E Glass UD
B) MODAL ANALYSIS:

Fig: Aluminium Alloy

Fig: Grey Cast Iron
Fig: Structural Steel
Fig: Epoxy E Glass UD
Sr.no Mode Natural Frequency(Hz)
Aluminium alloy
1 1 1558.4
2 2 2983.3
3 3 3141.1
4 4 3190.8
5 5 3262.4
6 6 3733.6
7 7 4304.6
8 8 4974.8
9 9 6121.4
10 10 6340.3

Sr.no Mode Natural Frequency(Hz)

Grey Cast Iron
1 1 1217.1
2 2 2309.9
3 3 2433.9
4 4 2474.1
5 5 2527.9
6 6 2883.8
7 7 3312.8
8 8 3879.7
9 9 4809.5
10 10 4978.4

Sr.no Mode Natural Frequency(Hz)

Structural Steel
1 1 1564.2
2 2 2978.8
3 3 3137.8
4 4 3189
5 5 3259.1
6 6 3722.9
7 7 4282.9
8 8 4989.1
9 9 6166.9
10 10 6385.1

Sr.no Mode Natural Frequency(Hz)

Epoxy E Glass UD
1 1 978.3
2 2 1374.9
3 3 1488.9
4 4 1820.9
5 5 2009.2
6 6 2016.9
 7 7 2036.7
8 8 2620.1
9 9 3096.5
10 10 3229.9

VALIDATION OF RESULT
Ref: M. KEERTHI1, K. SANDYA2, K. SRINIVAS3 Static & Dynamic Analysis of Spur Gear
using Different Materials”

These results from the above mentioned paper validate the results obtained by us
experimentally. It shows us that maximum deformation is seen in Epoxy composite and least
deformation is found in structural steel.

Modal analysis results also shows maximum frequency for structural steel and minimum for
epoxy composite which is seen as a similar trend from results obtained by us.
CONCLUSION
 Among the four materials chosen, i.e., Al alloy, structural steel, Epoxy E Glass UD and
grey cast iron, the epoxy composite has the least density with 1900 kg/m 3 , followed
by Al alloy (2200kg/m 3 ), grey cast iron(7200 kg/m 3 ) and structural steel( 7850 Kg/m
3 ).
 The static structural analysis results as tabulated in the results section shows that
maximum deformation occurs in the case of epoxy composite and it is the least in case
of structural steel.
 The results in the case of Von misses stress are similar for structural steel, grey cast
iron and Al alloy, i.e. in the range of 21MPa, but we see a significant rise to 25MPa for
epoxy composite.
 Detailed modal analysis revealed that natural frequencies are the least for Epoxy and
the most for structural steel. Inherent vibration modes in structural components can
shorten equipment life.
 Thus, the modal analysis reveals that using epoxy composite can enhance the life the
spur gear used. Selection of a material is done based on a combination of the above-
discussed factors.
 Each material has its limitations and advantages, but this analysis shows that Epoxy
composite can be a good fit for current gearboxes compared to the existing materials
used.
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