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1. Introduction
Bevel gears are used widely at different applications in Industrial Machinery, especially in the automotive industry. Since bevel gears have such a great range of applications, its crucial to be able to analyze their deformation under an applied load. In this work, our aim is to investigate the behavior of a bevel gear set under a given moment using Finite Element Analysis. The results are evaluated both numerically and analytically. For the analytic solution, formulas from Norton [1] is used. Finite element analysis is used as the numerical method. Autodesk Simulation Mechanical 2012 is used to perform finite element analysis.
# of tooth in Gear: Ng = 29 # of tooth in Pinion: Np = 17 Facewidth: F = 62.354 mm Gear pitch diameter: dg = 220 mm Pinion pitch diameter: dp = 130 mm Pressure angle: = 20o Spiral angle: = 35o Module: m = d/N = 7.58 mm
: Tooth root bending stress [Mpa] T : Torque applied or transformed to the gear/pinion [Nmm] d : Diameter of the gear/pinion [mm] F : Facewidth [mm] J : Geometry factor of the gear/pinion m: Module [mm] Ka: Application factor Km: Load distribution factor Ks: Size factor Kv: Dynamic factor Kx: Gear geometry factor (spiral/straight)
The analytical calculation is performed for the gear in our problem. The parameters and the result are given in the table at right above.
Figure 5.1: Top and Right views of the meshed bevel gear set
As stated above, Autodesk Simulation Mechanical 2012 is used to perform the finite element analysis. As the Analysis Type, Static Stress with Linear Material Models is chosen, since the model doesnt include any nonlinearity. As Mesh settings, an absolute surface mesh size of 6 mm is imposed. Solid mesh is set to the option All tetrahedral. Contact setting is left as the default setting, bonded. To get more accurate results, mesh of the contact region is refined. The vertices in the contact zone are selected as refinement points and they are forced to have the mesh size of 1.25 mm and the radius of 7 mm.
The boundary conditions and moment applied should be specified in the Load and Constraint Groups section. Since the tetrahedron element doesnt possess rotational degree of freedoms, separate beam joint elements should be defined, on which rotational degree of freedoms can be imposed. Two surfaces encapsulating the inner cylindrical area of the gear and the two surfaces encapsulating the cylindrical surface of the shaft connected to the pinion are selected and joints are added to these surface pairs. The two joint vertices of the gear are selected and fixed boundary conditions are imposed, whereas the two joint vertices of the pinion are imposed only one rotational degree of freedom, which is y direction in our model. The two vertices in the pinion joint are selected and imposed a moment of -300000 Nmm in y direction, which add up to -600000 Nmm, the desired amount for our model. For shorter solution times, contact region surfaces can be separated from their corresponding parts by assigning a new surface attribute to the participating line elements of each part. Then these contact surfaces should be selected and specified as in surface contact.
Figure 6.1: The gear mesh. The contact region has the finest elements
Figure 6.2: A closer look at the contact region. Pay attention to the contact pattern where the stresses are high
To calculate the tooth root bending stress, the vertices in the root region are selected and the mean stress is calculated. The mean, as it can be seen from the figure below, is 37,016 MPa.
To see the big picture more clearly, stress distribution plot of the root vertices are generated as can be seen below. It is to be observed that the stress values in general lie between 20-50 MPa. The values are concentrated between 35 and 40 MPa.
160 140 120 von Mises Stress [MPa] 100 80 60 40 20 0 -72 -67 -62 -57 -52 Position in z Direction [mm]
7. Discussion
We see a great similarity between the numerical and the analytical results. From the results evaluated, it can be said that the FEA Analysis is validated. The difference in between is caused by many factors. The accuracy of the FEA results may be increased by using more mesh elements, which encapsulate contact regions more densely. Also a smaller tolerance for the solution of the stiffness matrix can be imposed.
8. References
[1] Norton, Robert L., Machine Design: An Integrated Approach, Third Edition, 2006, Pearson Prentice Hall .