Strength Evaluation and Fatigue Prediction of a Spur Gear Pair by Computer Simulation

2006 ◽  
Author(s):  
Zhong Hu ◽  
Fereidoon Delfanian
Keyword(s):  
Computer Simulation ◽  
Mechanical Design ◽  
Gear Tooth ◽  
Three Dimensional ◽  
Spur Gear ◽  
Operating Conditions ◽  
Gear Pair ◽  
Working Cycle ◽  
Fatigue Design ◽  
Time Histories

Fatigue prediction of a three-dimensional mechanical component under dynamic load is critical for mechanical design. In this paper, computer simulation of three-dimensional dynamic stress followed by fatigue calculation was performed on a spur-gear pair using finite element modeling. Starting from gear pair geometry and operating conditions, the time histories of the dynamic loads and multi-axial stresses for a complete working cycle of a gear tooth were computed, and then post processed to produce fatigue strength information. Along with certain material properties obtained from experiments, this computer simulated fatigue design provides a useful tool for predicting fatigue failure of mechanical components.

Three-Dimensional CFD Analysis of Meshing Losses in a Spur Gear Pair

2018 ◽  
Author(s):  
T. Fondelli ◽  
D. Massini ◽  
A. Andreini ◽  
B. Facchini ◽  
F. Leonardi
Keyword(s):  
High Speed ◽  
Numerical Study ◽  
Fluid Dynamic ◽  
Three Dimensional ◽  
Spur Gear ◽  
Computational Domain ◽  
Gear Pair ◽  
Transient Pressure ◽  
Numerical Effort ◽  
Free Environment

The reduction of fluid-dynamic losses in high speed gearing systems is nowadays increasing importance in the design of innovative aircraft propulsion systems, which are particularly focused on improving the propulsive efficiency. Main sources of fluid-dynamic losses in high speed gearing systems are windage losses, inertial losses resulting by impinging oil jets used for jet lubrication and the losses related to the compression and the subsequent expansion of the fluid trapped between gears teeth. The numerical study of the latter is particularly challenging since it faces high speed multiphase flows interacting with moving surfaces, but it paramount for improving knowledge of the fluid behavior in such regions. The current work aims to analyze trapping losses in a gear pair by means of three-dimensional CFD simulations. In order to reduce the numerical effort, an approach for restricting computational domain was defined, thus only a portion of the gear pair geometry was discretized. Transient calculations of a gear pair rotating in an oil-free environment were performed, in the context of conventional eddy viscosity models. Results were compared with experimental data from the open literature in terms of transient pressure within a tooth space, achieving a good agreement. Finally, a strategy for meshing losses calculation was developed and results as a function of rotational speed were discussed.

Effect of Gear Tooth Crack on Spur Gear Dynamic Response by Simulation

2011 ◽  
Author(s):  
Yimin Shao ◽  
Xi Wang ◽  
Zaigang Chen ◽  
Teik C. Lim
Keyword(s):  
Dynamic Response ◽  
Gear Tooth ◽  
Sudden Change ◽  
Element Model ◽  
Spur Gear ◽  
Operating Conditions ◽  
Lumped Parameter Model ◽  
Mesh Stiffness ◽  
Heavy Load ◽  
High Rotational Speed

Geared transmission systems are widely applied to transmit power, torque and high rotational speed, and as well as change the direction of rotational motion. Their performances and efficiencies depend greatly on the integrity of the gear structure. Hence, health monitoring and fault detection in geared systems have gained much attention. Often, as a result of inappropriate operating conditions, application of heavy load beyond the designed capacity or end of fatigue life, gear faults frequently occur in practice. When fault happens, gear meshing characteristics, including mesh stiffness that is one of the important dynamic parameters, can be affected. This sudden change in mesh stiffness can induce shock vibration as the faulty gear tooth passes through the engagement zone. In this study, a finite element model representing the crack at the tooth root of a spur gear is developed. The theory is applied to investigate the effect of different crack sizes and the corresponding change in mesh stiffness. In addition, a lumped parameter model is formulated to examine the effect of tooth fault on gear dynamic response.

Plasto-Elastohydrodynamic Lubrication in Point Contacts for Surfaces With Three-Dimensional Sinusoidal Waviness and Real Machined Roughness

2014 ◽  
Vol 136 (3) ◽  
Author(s):  
Tao He ◽  
Ning Ren ◽  
Dong Zhu ◽  
Jiaxu Wang
Keyword(s):  
Plastic Deformation ◽  
Rough Surface ◽  
Mechanical Design ◽  
Three Dimensional ◽  
Elastohydrodynamic Lubrication ◽  
Operating Conditions ◽  
Von Mises Stress ◽  
Asperity Contacts ◽  
Lubrication Characteristics ◽  
Von Mises

Efficiency and durability are among the top concerns in mechanical design to minimize environmental impact and conserve natural resources while fulfilling performance requirements. Today mechanical systems are more compact, lightweight, and transmit more power than ever before, which imposes great challenges to designers. Under the circumstances, some simplified analyses may no longer be satisfactory, and in-depth studies on mixed lubrication characteristics, taking into account the effects of 3D surface roughness and possible plastic deformation, are certainly needed. In this paper, the recently developed plasto-elastohydrodynamic lubrication (PEHL) model is employed, and numerous cases with both sinusoidal waviness and real machined roughness are analyzed. It is observed that plastic deformation may occur due to localized high pressure peaks caused by the rough surface asperity contacts, even though the external load is still considerably below the critical load determined at the onset of plastic deformation in the corresponding smooth surface contact. It is also found, based on a series of cases analyzed, that the roughness height, wavelength, material hardening property, and operating conditions may all have significant influences on the PEHL performance, subsurface von Mises stress field, residual stresses, and plastic strains. Generally, the presence of plastic deformation may significantly reduce some of the pressure spikes and peak values of subsurface stresses and make the load support more evenly distributed among all the rough surface asperities in contact.

On the Coupling of Inverse Design and Optimization Techniques for Turbomachinery Blade Design

2006 ◽  
Author(s):  
Duccio Bonaiuti ◽  
Mehrdad Zangeneh
Keyword(s):  
Mechanical Design ◽  
Design Method ◽  
Three Dimensional ◽  
Axial Compressor ◽  
Optimization Techniques ◽  
Operating Conditions ◽  
Inverse Design ◽  
Design Parameters ◽  
Optimization Strategy ◽  
Design And Optimization

Optimization strategies have been used in recent years for the aerodynamic and mechanical design of turbomachine components. One crucial aspect in the use of such methodologies is the choice of the geometrical parameterization, which determines the complexity of the objective function to be optimized. In the present paper, an optimization strategy for the aerodynamic design of turbomachines is presented, where the blade parameterization is based on the use of a three-dimensional inverse design method. The blade geometry is described by means of aerodynamic parameters, like the blade loading, which are closely related to the aerodynamic performance to be optimized, thus leading to a simple shape of the optimization function. On the basis of this consideration, it is possible to use simple approximation functions for describing the correlations between the input design parameters and the performance ones. The Response Surface Methodology coupled with the Design of Experiments (DOE) technique was used for this purpose. CFD analyses were run to evaluate the configurations required by the DOE to generate the database. Optimization algorithms were then applied to the approximated functions in order to determine the optimal configuration or the set of optimal ones (Pareto front). The method was applied for the aerodynamic redesign of two different turbomachine components: a centrifugal compressor stage and a single-stage axial compressor. In both cases, both design and off-design operating conditions were analyzed and optimized.

The Finite Element Modeling and Analysis of Involute Spur Gear

2012 ◽  
Vol 516-517 ◽  
pp. 673-677 ◽  
Author(s):  
Shun Xu ◽  
Yan Zhang
Keyword(s):  
Finite Element ◽  
Mechanical Design ◽  
Three Dimensional ◽  
Spur Gear ◽  
Analysis Model ◽  
Element Analysis ◽  
Finite Element Analysis Model ◽  
Modeling And Analysis ◽  
Gear Mesh ◽  
Design Software

Through three-dimensional mechanical design software Pro/E to build a spur gear solid model, using ANSYS software for the gear mesh, as well as the constraints imposed by the most unfavorable load to determine the location of the discussion, in order to get accurate finite element analysis model. By analyzing, this shows that the effectiveness of the application of ANSYS in gear calculation.

scholarly journals Consideration of Moving Tooth Load in Gear Crack Propagation Predictions

2000 ◽  
Author(s):  
David G. Lewicki ◽  
Lisa E. Spievak ◽  
Paul A. Wawrzynek ◽  
Anthony R. Ingraffea ◽  
Robert F. Handschuh
Keyword(s):  
Crack Propagation ◽  
Dimensional Analysis ◽  
Gear Tooth ◽  
Contact Region ◽  
Three Dimensional ◽  
Spur Gear ◽  
Calculated Stress ◽  
Prediction Techniques ◽  
Gear Crack ◽  
Element Method

Abstract Robust gear designs consider not only crack initiation, but crack propagation trajectories for a fail-safe design. In actual gear operation, the magnitude as well as the position of the force changes as the gear rotates through the mesh. A study to determine the effect of moving gear tooth load on crack propagation predictions was performed. Two-dimensional analysis of an involute spur gear and three-dimensional analysis of a spiral-bevel pinion gear using the finite element method and boundary element method were studied and compared to experiments. A modified theory for predicting gear crack propagation paths based on the criteria of Erdogan and Sih was investigated. Crack simulation based on calculated stress intensity factors and mixed mode crack angle prediction techniques using a simple static analysis in which the tooth load was located at the highest point of single tooth contact was validated. For three-dimensional analysis, however, the analysis was valid only as long as the crack did not approach the contact region on the tooth.

scholarly journals A Multiobjective Optimization Analysis of Spur Gear Pair: The Profile Shift Factor Effect on Structure Design and Efficiency

2021 ◽  
Vol 2021 ◽  
pp. 1-10
Author(s):  
Samya Belarhzal ◽  
Kaoutar Daoudi ◽  
El Mostapha Boudi ◽  
Aziz Bachir ◽  
Samira Elmoumen
Keyword(s):  
Multiobjective Optimization ◽  
Power Transmission ◽  
Spur Gear ◽  
Shift Factor ◽  
Structure Design ◽  
Operating Conditions ◽  
Gear Pair ◽  
Contact Ratio ◽  
Face Width ◽  
Volume Equation

Spur gears are an indispensable element of power transmission, most of the time used in small environments with severe operating conditions such as high temperature, vibrations, and humidity. For this reason, manufacturers and transmission designers are required to look for better gear designs and higher efficiency. In this paper, a multiobjective optimization was conducted, using genetic algorithms (GAs) for corrected spur gear pair with an objective to reduce the structure volume and transmission power loss and reveal the influence of the profile shift factor on the optimal structure fitness. The optimization variables included are the pinion and wheel profile shift factors in addition to the module, face width, and the number of pinion teeth mostly used in standard gear optimization. The profile shift factor influences the shape of the gear teeth, the contact ratio, and the load sharing. It affects then the optimal results meaningfully. The gear pair volume, center distance, and efficiency presented the objective functions while contact stress, bending stress, face with coefficient, and tooth tip interferences served as constraints. Furthermore, a volume equation was developed, in which a bottom clearance formula is included for more accurate results. "Multiobjective optimization" is conducted at medium and high speeds, and the results show that the structure design is compact compared to standard gears with reasonable efficiency for medium contact ratio.

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