Finite Element Simulation of Bending Stress on Involute Spur Gear Tooth Profiles

Author(s):  
Kolawole Adesola Oladejo ◽  
Dare Aderibigbe Adetan ◽  
Ayobami Samuel Ajayi ◽  
Oluwasanmi Oluwagbenga Aderinola

This study investigated bending stress distribution on involute spur gear tooth profiles with pressure angle of 20 ̊ but different modules 2.5, 4.0 and 6.0 mm, using a finite-element-based simulation package - AutoFEA JL Analyzer. The drafting of the geometry for the three gear tooth profiles were implemented on the platform of VB-AutoCAD customized environment, before importing to the package. These were separately subjected to analysis for bending stresses for a point at the tooth fillet region with appropriate settings of material property, load and boundary conditions. With the same settings, the bending stresses were computed analytically using American Gear Manufacturers Association (AGMA) established equation. The results of the two approaches were in good agreement, with maximum relative deviation of 4.38%. This informed the confidence in the implementation of the package to investigate the variation of bending stress within the gear tooth profile. The simulation revealed decrease in the bending stresses at the investigated regions with increase in the module of the involute spur-gear. The study confirms that Finite element simulation of stresses on gear tooth can be obtained accurately and quickly with the AutoFEA JL Analyzer.

1994 ◽  
Vol 116 (4) ◽  
pp. 1157-1162 ◽  
Author(s):  
G. D. Bibel ◽  
S. K. Reddy ◽  
M. Savage ◽  
R. F. Handschuh

Thin rim gears find application in high-power, lightweight aircraft transmissions. Bending stresses in thin rim spur gear tooth fillets and root areas differ from the stresses in solid gears due to rim deformations. Rim thickness is a significant design parameter for these gears. To study this parameter, a finite element analysis was conducted on a segment of a thin rim gear. The rim thickness was varied and the location and magnitude of the maximum bending stresses reported. Design limits are discussed and compared with the results of other researchers.


Author(s):  
Yan Gao ◽  
Rui Zhou ◽  
Yu-Cheng Wu ◽  
Heng-Li ◽  
Wen-Lin Chen ◽  
...  

The cold ironing process of a warm forged spur gear was applied to investigate the elastic distortions arising by the behavior of die elastic expansion and gear elastic recovery in this article. An elasto-plastic finite element simulation was performed to analyze the elastic behavior characteristics of gear and die. The effects of interference between gear and die on the elastic distortions were investigated through finite element simulation and experiment, respectively. The change of geometrical profile and dimension of the gear tooth were measured; the estimated dimension of ironed gear by finite element simulation was fitted to the experimental results well within the range of 5% relative error. Furthermore, in order to improve the dimensional accuracy of final forged gear, this study proposed a die cavity compensation method to compensate cavity of the ironing die, which was obtained by shrink fitting a outer ring into the initial ironing die. The optimum radial interference between stress ring and initial shrink-fitted die was calculated based on the Lame formula and thick wall cylinder theory. Finally, an experiment according to the proposed die cavity compensation method was carried out to examine the validity of analytical results and demonstrated that predicted dimensions could be achieved and dimensional accuracy greatly improved. It was shown that the manufacture gear satisfies the IOS6 class by measuring the iron-forged gear.


Author(s):  
Zihni B Saribay

The conjugate meshing face-gear pairs are implemented to high shaft angle intersecting axis gears such as the pericyclic transmission system. The meshing face-gear pair tooth surfaces are generated with a mutually conjugate spur shaper. The established tooth geometry and the dimensions of the conjugate face-gear pairs are summarized in this article. Four different example face-gear pairs are generated at various shaft angles and numbers of tooth combinations. Tooth bending stresses of these face-gear pair teeth are investigated based on finite element analysis methods. In these analyses, only single pairs of teeth are investigated. These results are compared to analog the spur gear tooth bending stresses calculated by finite element analysis and standard spur gear stress formulas. Meshing face-gear pair single tooth bending stress levels show approximately 3% to 6% difference from same size spur gear tooth.


2007 ◽  
Vol 340-341 ◽  
pp. 353-358 ◽  
Author(s):  
M. Loh-Mousavi ◽  
Kenichiro Mori ◽  
K. Hayashi ◽  
Seijiro Maki ◽  
M. Bakhshi

The effect of oscillation of internal pressure on the formability and shape accuracy of the products in a pulsating hydroforming process of T-shaped parts was examined by finite element simulation. The local thinning was prevented by oscillating the internal pressure. The filling ratio of the die cavity and the symmetrical degree of the filling was increased by the oscillation of pressure. The calculated deforming shape and the wall thickness are in good agreement with the experimental ones. It was found that pulsating hydroforming is useful in improving the formability and shape accuracy in the T-shape hydroforming operation.


2020 ◽  
Vol 858 ◽  
pp. 14-19
Author(s):  
Michael May

In the context of automotive crash simulation, rate-dependent properties are sought for all materials undergoing deformation. Measuring rate-dependent properties of adhesively bonded joints is a challenging and associated with additional cost. This article assesses the need for having rate-dependent properties of adhesively bonded joints for the example of a typical automotive structure, an adhesively bonded metallic T-joint. Using Finite Element simulation it could be shown that good agreement between experiment and simulation was only achieved if rate-dependent properties were considered for the adhesive.


2013 ◽  
Vol 554-557 ◽  
pp. 300-306 ◽  
Author(s):  
Alireza Khodaee ◽  
Arne Melander

Gear rolling is a manufacturing technique for gears with many advantages like reduced material consumption, reduced scrap generation, fast cycle times, good surface quality and improved final properties of the gear wheels compared to conventional production technology based on machining. In order to make use of all these advantages it is desired to reach the final shape of the gear wheel already after rolling. This means that post treatments like grinding should be avoided. This puts high requirements on the shape accuracy after gear rolling. In this paper it was studied if finite element simulation could be used to evaluate the shape accuracy after gear rolling. The measurement of shape accuracy of gear wheels is specified in standards like ISO1328-1. The allowed deviations from nominal shape are often of the order of 10-30 μm for very good qualities. So if such evaluation shall be possible from a finite element simulation the accuracy must be of the same order. In order to have sufficient accuracy of the finite element simulation 2D simulations were performed on a spur gear. The FE code DEFORM was utilized. The shape accuracy was evaluated for gear rolling of two cases. One case had gears with the module of 1 mm. The other case involved gears with a significantly larger module of 4 mm. This was an interesting case since it is known that it is more difficult to roll the gear with good accuracy in large modules.


2014 ◽  
Vol 983 ◽  
pp. 226-230
Author(s):  
Zhu Dan ◽  
Zheng Yan

Machining of metals make use of thermal mechanical FEM model. Analysis of nonlinear elastoplastic finite element simulation of milling of 45 # steel material use software of ABAQUS that is finite element simulation technology. ABAQUS software could be carried out on prediction of the milling force. Through finite element analysis, distribution of stress field of workpiece and tool is obtained under the influence of thermal mechanical. The prediction accuracy of the model was validated experimentally and the obtained numerical and experimental results were found in good agreement.


2003 ◽  
Vol 125 (2) ◽  
pp. 365-372 ◽  
Author(s):  
Ming-Jong Wang

In this paper, the maximum tensile bending stress (MTBS) and the critical point in the root fillet of spur gear tooth during transmission are determined by a digital photoelastic system involving real time imaging. The behavioral characteristics of the bending stresses of the gear tooth are analyzed at different rotation speeds, transmitted torques, and contact points. Then, the dynamic effects, the various critical points and the maximum tensile bending stresses are compared experimentally and theoretically, and discussed. Finally, the best approaches for determining the maximum bending stress and its position in the root fillet of spur gear tooth are recommended.


Author(s):  
F. Karpat ◽  
S. Ekwaro-Osire ◽  
T. G. Yilmaz ◽  
O. Dogan ◽  
C. Yuce

In recent years, thanks to their significant advantages such as compactness, large torque-to-weight ratio, large transmission ratios, reduced noise and vibrations, internal gears have been used in automotive and aerospace applications especially in planetary gear drives. Although internal gears have a number of advantages, they have not been studied sufficiently. Internal gears are manufactured by pinion type cutters which are nearly identical with pinion gear except the addendum factor which is 1.25 instead of 1. The tip geometry of a pinion type cutter which determines the fillet of internal gear tooth can be sharp or rounded. In this study, the design of internal gears were investigated by using a traditional approach. Mathematical equations of pinion type cutter were obtained by using differential geometry, then the equations of internal gear tooth were derived accurately by using coordinate transformations and relative motion between the pinion type cutter and internal gear blank. A computer program was generated to attain points of internal gear teeth and three dimensional design of complete gear. 20°-20° were used as pressure angle. To find optimum internal gear geometry, different rim thicknesses and shapes are tried out for finite element analyses. There were several parameters that were shown to effect the performance of the internal gears, with tooth stiffness being the most significant parameter. Tooth stiffness was also vitally influence the dynamic analysis. In order to compute gear tooth stiffness of the internal gear with various rim thicknesses and shapes, finite element analysis was used. A static analysis was performed to assess the gear bending stress and tooth displacement. Tetrahedral element type was selected for meshing. The internal gear outer ring was fixed and the force of 2500 N was applied on the tooth. According to the displacement values from the analysis internal gear tooth stiffness were calculated individually. Additionally, the effect of root bending stress with varying rim thickness, shapes, and root radius were investigated. The bending stresses were calculated according to ISO 6336 and using finite element analysis were shown to be in good agreement. It was shown that when the rim thickness and fillet radius were increased, the maximum bending stresses decreased considerably. As rim thickness was increased, the maximum bending stress decreased nearly 23%. It was also shown that as the fillet radius decreased, the maximum bending stress increased, whereas the rim stresses slightly changed. As the fillet radius was decreased, the maximum bending stress increased nearly 10%. It was also observed that when rim thickness was increased, the stress on the rim was decreased, whereas tooth stiffness was increased. However, fillet radius had no visible effect both on rim stress and tooth stiffness. Furthermore, it was shown that the rim shape had significant effect on rim stress.


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