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MET 2014-02
Fillet

533040594-0
533040595-8
543040863-0

.. 2557
Project Report No. MET 2014-02
A study of effect of gears root fillet profile on spur gear failure based on
finite element analysis.
Sarun Turakam
Saranyoo Kulrat
Witawan Chompoobud
ID 533040594-0
ID 533040595-8
ID 543040863-0
This is the report of fourth year project assignment submitted in partial

fulfillment of the requirement for the Degree of Bachelor of Engineering.
Department of Mechanical Engineering

Faculty of Engineering, Khon Kaen University
2014
Fillet

A study of effect of gears root fillet profile on spur gear failure based
on finite element analysis

533040594-0
533040595-8
543040863-0
.......
( .. )

1. .......
( .. )
2. .......
( . )
3. .......
( .. )
23 2557

ME 2014-02 .

. .
.

Fillet

P 96 10 4 1500
, 2000 , 2500 , 3000 , 3500 4000 , 4000 , 4500 , 5000 , 5500 , 6000 20o
-1 , -0.5 , +0.5 +1
0.001
: , , ,

ABSTRACT
This project is to study the impact of the model Fillet at the base of the gear teeth on the Finite
element method to the damage that occurs to the gear teeth. By fix the gear in place and apply force to the
surface of the gear. Which may be damaged due to bending stresses at the base of the gear. To apply force
to the surface of the gear will cause a gear bending stresses. This causes gear damage. It was designed for a
range of fillet appropriate Sprockets and analyzed bending stresses that occur on the gear backlash. By use
of the finite element method at size diameter pitch P 96 mm thickness of gear 10 mm module 4 mm and
force press 1500, 2000, 2500, 3000, 4000, 3500, 4000, 4500, 5000, 5500, 6000 Newton, pressure angle 20o
and shift radius of a fillet from the standard size -1, -0.5, -0.5 and + 1 mm to find a appropriate mesh. The
results of the test gear with a mesh size of 0,001 meters.
Keywords: Radius of fillet, Spur gear, Angle press , Module.

1
1.1
1.2
1.3
1.4
1.5
1.6
2
2.1
2.2
2.3
3
3.1 Ansys
3.2 Physical Model
3.3 Validate
4
4.1 1 Diameter fillet standard -1 mm
4.2 2 Diameter fillet standard -0.5 mm
4.3 3 Diameter fillet standard +0.5 mm
4.4 4 Diameter fillet standard +1 mm
5
5.1
5.2
1
2
2
2
2
3
3
4
4
20
28
32
32
33
34
41
41
42
43
44
45
45
45
46
47

2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11

Circular Pitch

Single Stage Gear Train
Single Stage with Idle Gear Train
(Single Stage Gear Pair)
Two Stage with Idle Gear Train
StressStrain

J rf = 0.35F = 20 = 25
AGMA
x y
Ansys
Physical Model
3
2
2
Boundary Conditions
Gear : Pitch
Mesh Size Stress

Stress Ansys
Maximum Bending Stress
4 Pressure Angle 20 (10^6 N/m^2)

4
5
6
6
9
9
10
11
12
14
14
15
18
20
23
27
28
32
33
34
34
35
35
36
36
37
37
39
( )
3.12
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
5.1
5.2
5.3
5.4
5.5
Fillet
Mesh 1
Stress 1
Mesh 2
Stress 2
Mesh 3
Stress 3
Mesh 4
Stress 4
Drawing
Drawing Model 01
Drawing Model 02
Drawing Model 03
Drawing Model 04

40
41
41
42
42
43
43
44
44
48
49
50
51
52

2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
3.1
3.2
3.3
3.4

2.9

Values of AGMA Lewis form factor Y*
AGMA Geometry factor, J For Teeth
Parameter

7
12
13
16
19
22
25
25
26
26
33
38
38
39
AGMA
b
C
Cp
d
Ft
Fr
J
Kf
i
I
M
mG
mN
m
NP
NG
N
n
p
rf
Y
Z
max
The American Gear Manufacturers Association

(m)
Circular Pitch (mm)
Geometry factor

(m4)
(N-m)
(Mesh Ratio)

Module , (m)
(Teeth on Pinion or Driving)
(Teeth on Gear or Following)

(rpm)
(mm)

Lewis form factor

Pi , 22/7

(rad)
1.1
(Gear)

(Pitch) (Module)
(Addendum) (Dedendun)

Fillet

(Bending Stress) Fillet
(Stress Concentration)
Fillet
(Rack Cutter) 0.3/
Fillet

Fillet
Fillet

Fillet
Fillet
1.2
1.2.1
1.2.2 Fillet
1.2.3 Fillet
1.3
Fillet
Static
ANSYS
1.4
1.4.1
1.4.1.1
1.4.1.2 Ansys
1.4.1.3 3
1.4.1.4 Boundary Condition
1.4.1.5 Element
1.4.2
1.4.2.1 Boundary condition
1.4.2.2 Element
1.4.2.3 Validate Model Bending Stress Exact Solution
Ansys
1.4.2.4 Fillet Mesh
Ansys
1.5
1.1
2556
10 11 12 1
Pre - Project
Ansys
FEM
Element
Project
Boundary
Condition
Validate model Bending
Stress
Exact solution
mesh size
Element
Simulation
Fillet

1.6
1.6.1
1.6.2 Fillet
2557
6 7
9 10 11 12
2.1

(Addendum)
(Dedendum) (Depth) (Clearance) (Pressure Angle)

( 2.1 )
2.1
( http://www.thailandindustry.com/guru/view.php?id=13678&section=9 )
2.2 Circular Pitch

2.1.1 (Tooth Proportions)
2 (Metric)
(Module)

(DP=Diameter Pitch)

2.1.2 (Module, M)

(Module, m)
, m = Cp(1)
Circular Pitch, Cp = m ... (2)
Cp Circular Pitch , mm
3.14
2.3
2.1.3 DP (Diametral Pitch, DP)
(DP Gear) Diametral
Pitch 1
N
DP = . (3)
PD
DP , /,
N
PD ,
2.4
DP = 48 48
1
2 48
48/2 = 24 / 24 2
24/2 = 12/
2.1.4 (Module, m) ( )

2.57
m = (4)
Cp
Cp Circular Diameter Pitch, mm

Cp = m ... (5)
2.1 64 /
Cp = [ 25.4 (1)] / 64 = 1.24682 mm
(m) 2.54/1.24682 = 3.9688 mm 2.1
2.1
2.1.5

(Module, M) Diametral Pitch, DP
2.1.5.1 Circular Pitch, p
(Pitch Circle)
d
p = (6)
N
p = m ........... (7)
p , mm
m
N
2.1.5.2 Base Diameter
2.1.5.3 Backlash

2.1.5.4 (Center Distance)
2.1.5.5 (Circular Thickness)

2.1.5.6 (Outside Diameter)

2.1.5.7 (Pressure Angle)
(Tangent) 21

(Spur
Gear)
2.5 Pressure Angle
Tangent
Tangent (Pressure Angle)
(Pressure Angle) 14.5 , 20 25

ANSI 20
(Load) (Pressure Angle) 25

(Pressure Angle)
14.5
2.5
(Pressure Angle)

2.6 Single Stage Gear Train

10
2.1.6 (Gear Ratio, Mesh Ratio, mG)

(Single Stage Gear Train)
(Mashing)
N
NP
Z1
n2
mG = G = 2 = 1 (8)
mG (Mesh Ratio)
NG, z2 (Teeth on Gear or Following),
NP, z1 (Teeth on Pinion or Driving),
n1 , rpm
n2 , rpm
(Idle Gear) Single Stage
with Idle Gear Train
Z
Z1
Z2
Z1
mG = 2 = 3 = 3 .. (9)

10

2.7 Single Stage with Idle Gear Train

11
2.8 (Single Stage Gear Pair)

(Two Stage Gear Train)
2.9
Z
mG = 2 x 4 = 1 x 3 .. (10)
Z1 Z3
n2 n4
Single Stage with Idle Gear Train

2
2 3
10
12
2.9 Two Stage with Idle Gear Train


2.9 1 10 (z1 = 10)
2 24 (z2 = 24) 3 12 (z3 = 12) 3
2 4 30 (z4= 30)
2 1
2 2 3 4
2.2 2.9
13
2.1.7 (Gears Material)

(Bending Allowable) (Hertz Stress, Hertz (Contact) Stress?)
(Wear Resistance) (Impact Strength)
(Corrosion Resistance) (Manufacturing Cost)

Off Road

2.1.7.1 (Plastic)
(Load)
(Polymer)
(Nylon) (Polyimide)

(Load)
(MC Nylon)
2.3
14
2.3
121 Co
(Yield Strength) 81 MPa

StressStrain
2.10 StressStrain
2.11
15
2.12

(Water Absorbsion) 2.3
1.5%

100%, 50%

2.1.7.2 (Nonferrous Metal)
2.1.7.2.1 (Aluminum)

(Sliding)

16
2.1.7.2.2 (Titanium)
(Slide)

2.1.7.2.3 (Copper Alloy)
(Bronze)

(Worm Gear)

(Yield Strength)
138414 MPa

2.4
2.1.7.3 (Cast Iron)

17
(Sliding)

(Impact Load or Shock
Load) (Malleable Iron) (Ductile Iron)
Heat Treatments
(Bending Strength) 34 172 MPa
345 739 MPa

(Sliding)
2.1.7.4 (Sintered Powder Metals)

(Powder)

(Accuracy)
2.1.7.5 (Hardness Steel) (Load)
(High Accuracy)

(Load)
18
2.13
(Speed) (Lubrication)

Heat Treatment
(Bending Stress) 138 MPa
(Hertz Stress, Hertz (Contact) Stress) 586 MPa (Load)
(Surface Heat Treatment)
(Carburizing)
(Nitriding)

(Medium Carbon) (Bending Stress) 345414Mpa
(Hertz Stress, Hertz (Contact) Stress) 1,140 MPa
19

(Sliding)
2.5
20
2.2
2.2.1 Lewis
1892 Wilfred Lewis

Lewis
2.2.1.1 Ft Fr
2.2.1.2 max 1.251.40 1

2.2.1.3 Ft
b
> 6
p
,
2.2.1.4
Lewis 2.14 )
l Ft b t
A
=
M 6Ft l
=
IC bt2
....................(11)
D
E
2.14
( 2 )
21
13 ) F
Ft (11) 2.14 )
l b (11)
b 2
l = ( ) = t2 ....................(12)
6Ft
(12) parabola 2.14 )

2.14 )
a
2.14 ) CDE BDC
CD/DE=BD/CD
t l
2
=
x t2
1 t2
l = ( ) ....................(13)
4 x
1) 3)
1 bt2 1 bt2 2 x
Ft = ( ) = ( 2 ) = b ( ) p
6 l
6 t 4x 3 p
Ft = byp ....................(14.1)
2 x
y = ( ) = Lewis form factor circular pitch,p

3 p
(14.1) Ft = by ( ) ; [pP=]
Y
Ft = b =bYm ....................(14.2)
P
Y = y = Lewis form factor Diametral Pitch,P

2.6
22
2.6 Values of AGMA Lewis form factor Y*

( 1 )
2 x
Y x P y = ( )
3 p
2 x
3 p
Y = y = ( ) = x ( ) ; [pP=]
2
Y= xP ....................(15)
3
Y (15)
Lewis
1.5 5
run-in

Lewis form factor

1
Y= cosL 1.5 tanL ....................(16)

[ - t ]
cosL x
23
L = F

x t 2.15 L

2.15
( 2 )
2.2.2
Lewis
Dolan Broghamer
Photoelastic Kt (17.1)
t 0.2 t 0.4
0.22 + ( ) ( )
rf
l
0.15
t
t 0.45
Kt = 0.18 + (r )
f
()
l
; = 14
; = 20 ....................(17.1)
t 0.11 t 0.5
{0.14 + (rf) (l) ; = 25

Mitchiner and Mabie Kt Kf (17.2) Kf

t L t M
Kf = H + ( ) ( )
r
....................(17.2)
H = 0.340 - 0.4583662
L = 0.316 - 0.4583662
M = 0.316 - 0.4583662
24
(b - r )2
r = rf + (d )+f
2
b - rf
....................(17.3)
rf =
=
b =
d =
Kf =
(Fatigue strength reduction factor)
2.2.3 Geometry Factor
(14.2) Ft

Ft P
....................(18)
bY

Ft P
= Kf mN
bY
Ft P
=
....................(19)
bJ
J =
J=
Y
Kf mN
= Geometry factor AGMA ....................(20)
Kf = (fatigue stress concentration factor)

mN =
Lewis form factor,Y (20)
Ft ( H 14 )
(Load sharing ratio) mN = 1 J
Kf
....................(21)
Y = Lewis form factor (16) Y 6 geometry

factor, J (21) = 20 = 25
2 5 J Mitchiner and Mabie
J rf = 0.35F = 20 = 25 AGMA
25
2.7 AGMA Geometry factor, J For Teeth

( 2 )

( 2 )
26

( 2 )

( 2 )
27
2.16 J rf = 0.35F
= 20 = 25 AGMA
( 2 )
28
2.3
( Regression Analysis )
( Independent variable) X
( Dependent variable) Y

2.17
y
x
2.17 x y
( http://lms.mju.ac.th/courses/350/locker/st301/%207.doc )
29

2.3.1 (Simple Regression Analysis)

(Multiple Regression)
Yi 0 Xi i
y ( y - intercept)
(slope)
Yi 0 Xi
Yi b 0 bXi
2.3.2
OLS (Ordinary Least Square)
SSE
e i2
i 1
( Xi X)( Yi Y)
i 1
( Xi X)
i 1
b0 Y- b X
n
n
n
n Xi Yi Xi Yi
i 1
i 1 i 1
n
n
i 1
Xi2
Xi
i 1
30
2.3.3 0
2.3.3.1 (1 )100 % 0
b0 t
x S b0
2 ,n2
S b2o
S 2y.x X i2
i 1
i 1
i 1
n X i2 ( X ) 2
2.3.3.2 (1 )100 %
b t
x Sb
,n 2
S b2
S 2y.x
n
2
( X )
n
Xi2 i1n
i 1
2.3.4 (Standard Error of Estimate =
S y. x )
S y. x S 2y. x
S 2y. x
SST
Yi Y
n
i1
Yi2
i1
e i2
i 1
n2
SSE
n2
SST = SSR + SSE

n
Yi
i1
n
SST SSR
n2
n
n
SSR b ( Xi X)( Yi Y) b Xi Yi i1
i1
SSE SST - SSR
n
n
Xi Yi
i1 i1
n
31
2.3.5 (Coefficient of Determination = r2)

r2
SSR
SST
n
n
n
n Xi Yi Xi Yi
i 1
i 1 i 1
2
2
n
n
n
n
n Xi2 Xi n Yi2 Yi
i 1
i 1 i 1
i 1
r2 0 1
2.3.6 (Correlation Analysis )
2
r
n
n
n
n Xi Yi Xi Yi
i 1
i 1 i 1
2
2
n
n
n 2 n

2
n Xi Xi n Yi Yi
i 1
i 1 i 1
i 1
n
n
Xi Yi
n
i 1 i 1
Xi Yi
n
i 1
n
X
i
n 2 i 1
Xi
n
i 1
2

n

Y
n
i
Yi2 i 1
n
i 1
r -1 1
32
3.1 Ansys
Ansys 7.5 MPa 3.1
3.1 Ansys
Ansys Workbench 14.0
(Stress)
(Displacement)
(Exact solution)
33
3.2 Physical Model

3.2
3.2 Physical Model

( http://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/19860005142_1986005142.pdf )
3.1 Parameter
Parameter
Pressure Angel
Number of Tooth
Diameter
Pitch
Module
Value
20
24
96
12.57
4
Unit
Degree
Unit
mm
mm
mm
34
3.3 Validate
Bending Stress Ansys
Exact Solution Ansys
3.3.1 3
AGMA ANSI
3 3.3 , 3.4 3.5
3.3 3
3.4 2
35
3.5 2
3.3.2 Boundary Condition
1500 N 150
Boundary Conditions Fixed
Support 3.6
3.6 Boundary conditions
36
3.3.3 Element
3.7
3.7 Gear : Pitch

Stress Mesh Size
Mesh Size 0.23 3.8
3.8 Mesh size Stress
37
3.3.4 Validate Model Bending Stress

Exact Solution Ansys
3.9
3.9
( http://research.rdi.ku.ac.th/world/cache/95/SermsakKATAll.pdf )
Ansys 105.09 MPa 3.10
3.10 Stress Ansys
38
3.2
b (m)
0.01
m (m)
0.004
Presure Angle (Degree)
20
Number of tooth (Unit)
24
Lewis form factor Y
0.45
3.3 Ansys
Fn (N)
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
Fb (N)
1410
1879
2349
2819
3289
3759
4229
4698
5168
5638
th (Pa)
78307718
104410291
130512864
156615437
182718010
208820582
234923155
261025728
287128301
313230874
th (MPa)
78.31
104.41
130.51
156.62
182.72
208.82
234.92
261.03
287.13
313.23
Ansys (MPa)
99.61
132.81
166.01
199.21
232.41
265.62
298.82
332.02
365.22
398.42
39

Lewis Ansys 3.11
Bending Stress (10^6 N/m^2)

4 Pressure Angle 20 (10^6 N/m^2)
450.00
400.00
350.00
300.00
250.00
200.00
150.00
100.00
50.00
0.00
Theoretical
Actual
1000
2000
3000
4000
5000
6000
7000
Force (N)
3.11 Maximum Bending Stress 4

Pressure Angle 20 (10^6 N/m^2)
Ansys

= (MPa), = (MPa)
3.4
Fn (Number)
1
2
3
4
5
6
7
8
9
10
Total
xi
78.31
104.41
130.51
156.62
182.72
208.82
234.92
261.03
287.13
313.23
1957.69
yi
99.61
132.81
166.01
199.21
232.41
265.62
298.82
332.02
365.22
398.42
2490.15
xi2
6132
10902
17034
24528
33386
43606
55189
68134
82443
98114
439467
yi2
9921
17638
27559
39685
54014
70554
89293
110237
133386
158738
711027
xi yi
7800
13867
21666
31199
42465
55467
70200
86666
104865
124797
558993
40
r = 0.999999999689187 (MPa) (MPa)

99.9999999689187%
r2 = 0.999999999378373 (MPa)
(MPa) 99.9999999378373% 0.00000006217%

Fillet
3.3.5 Fillet
Fillet Mesh
Ansys

3.12
3.12 Fillet
41
4.1 1 Diameter fillet standard -1 mm

4.1.1 Mesh 1 Mesh 0.15
4.1
4.1 Mesh 1
4.1.2 Maximum normal stress 1 Stress 142.5
MPa 4.2
4.2 Stress 1
42
4.2 2 Diameter fillet standard -0.5 mm

4.2.1 Mesh 2 Mesh 0.07
4.3
4.3 Mesh 2
MPa 4.4
4.4 Stress 2
43
4.3 3 Diameter fillet standard +0.5 mm

4.3.1 Mesh 3 Mesh 0.19
4.5
4.5 Mesh 3
MPa 4.6
4.6 Stress 3
44
4.4 4 Diameter fillet standard +1 mm

4.4.1 Mesh 1 Mesh 0.1
4.7
4.7 Mesh 4
MPa 4.8
4.8 Stress 4
45
5.1
5.1.1 Mesh 1, 2, 3 4 0.15 ,
0.07 , 0.19 0.1
5.1.2
1,2,3 4 142.5 MPa, 118.89
MPa, 97.409 MPa 92.21 MPa
5.1.3 4
Stress concentration 4 4
5.2

P 96 10 4
1500 , 2000 , 2500 , 3000 , 3500 4000 , 4000 , 4500 , 5000 , 5500 , 6000
20o -1 , -0.5 , +0.5 +1
Full Depth Pressure Angel 20o

Pressure Angel 20 o

46
John J. Coy. (1985). Gearing. 31 2556,

http://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/19860005142_1986005142.pdf
Kawaguchi-shi. (2006). Gear technical reference. 24 2556,
http://www.khkgears.co.jp/en/gear_technology/pdf/gear_guide1.pdf
Kawaguchi-shi. (2006). Introduction to Gears: First Edition. 24 2556,
http://www.khkgears.co.jp/kr/gear_technology/pdf/gear_guide_060817.pdf
R.C Hibbeler, Statics And Mechanics Of Materials. Edition 2, Pearson Prentice Hall
BudynasNisbett. Shigleys Mechanical Engineering Design. Eighth Edition, McGrawHill Primis
. (2552). 10 2556,
http://thailandindustry.com/guru/view.php?id=9556&section=9..
.(...). 9 2556,
ite.rmu.ac.th/files/ 2.doc
. 1.:
, 2534.
. 2.:
, 2534.
.(2554). 25 2556,
http://www.thailandindustry.com/guru/view.php?id=13479&section=9
: . (2553). 11 2556,
http://siamkaewkumsai.blogspot.com/2010/06/fatigue.html
. 1 2557
http://lms.mju.ac.th/courses/350/locker/st301/%207.doc
47
48
5.1 Drawing
49
5.2 Drawing Model 01
50
51
52

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MET 2014-02

Project Report No. MET 2014-02

This is the report of fourth year project assignment submitted in partial

Department of Mechanical Engineering

The American Gear Manufacturers Association

2.2 Circular Pitch

Cp Circular Diameter Pitch, mm

2.1.5.5 (Circular Thickness)

(Pressure Angle) 14.5 , 20 25

(Load) (Pressure Angle) 25

2.6 Single Stage Gear Train

2.1.6 (Gear Ratio, Mesh Ratio, mG)

2.7 Single Stage with Idle Gear Train

2.8 (Single Stage Gear Pair)

Single Stage with Idle Gear Train

2.9 Two Stage with Idle Gear Train

2.1.7 (Gears Material)

2.1.7.3 (Cast Iron)

(12) parabola 2.14 )

y = ( ) = Lewis form factor circular pitch,p

Y = y = Lewis form factor Diametral Pitch,P

2.6 Values of AGMA Lewis form factor Y*

Y= cosL 1.5 tanL ....................(16)

{0.14 + (rf) (l) ; = 25

= Geometry factor AGMA ....................(20)

Kf = (fatigue stress concentration factor)

Y = Lewis form factor (16) Y 6 geometry

2.7 AGMA Geometry factor, J For Teeth

2.8 AGMA Geometry factor, J For Teeth

2.9 AGMA Geometry factor, J For Teeth

2.10 AGMA Geometry factor, J For Teeth

OLS (Ordinary Least Square)

2.3.4 (Standard Error of Estimate =

SST = SSR + SSE

SSE SST - SSR

2.3.5 (Coefficient of Determination = r2)

3.2 Physical Model

3.2 Physical Model

3.6 Boundary conditions

3.7 Gear : Pitch

3.8 Mesh size Stress

3.3.4 Validate Model Bending Stress

3.10 Stress Ansys

Presure Angle (Degree)

Number of tooth (Unit)

Lewis form factor Y

Maximum Bending Stress

Bending Stress (10^6 N/m^2)

Maximum Bending Stress

3.11 Maximum Bending Stress 4

r = 0.999999999689187 (MPa) (MPa)

4.1 1 Diameter fillet standard -1 mm

4.2 2 Diameter fillet standard -0.5 mm

4.3 3 Diameter fillet standard +0.5 mm

4.4 4 Diameter fillet standard +1 mm

John J. Coy. (1985). Gearing. 31 2556,

5.2 Drawing Model 01

5.3 Drawing Model 02

5.4 Drawing Model 03

5.5 Drawing Model 04

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