INTERNATIONALJOURNALOFAPPLIEDENGINEERINGRESEARCH,DINDIGUL

Volume1,No1,2010
Copyright2010AllrightsreservedIntegratedPublishingAssociation
RESEARCHARTICLEISSN09764259

Design,ModellingandManufacturingofHelicalGear
B.Venkatesh1 V.Kamala2 A.M.K.Prasad3
1

Assoc.Prof,MED,VardhamanCollegeofEngg,Hyderabad,India
Professor,MED,MJCET,HyderabadDGM(Retd),BHELR&D,Hyderabad,India
3
Professor,&Head,MED,OsmaniacollegeofEngg,OsmaniaUniversity,Hyderabad,India
bvt_2275@yahoo.co.in
2

ABSTRACT
Marineenginesareamongheavydutymachineries,whichneedtobetakencareofinthebest
way during prototype development stages. These engines are operated at very high speeds
which induce large stresses and deflections in the gears as well as in other rotating
components.Forthesafefunctioningoftheengine,thesestressesanddeflectionshavetobe
minimized. In this work, structural analysis on a high speed helical gear used in marine
engines, have been carried out. The dimensions of the model have been arrived at by
theoretical methods. The stresses generated and the deflections of the tooth have been
analyzed fordifferentmaterials. Finally the resultsobtainedby theoretical analysis and
FiniteElementAnalysisarecomparedtocheckthecorrectness.Aconclusionhasbeen
arrived on the material which is best suited for the marine engines based on the results.
Basically the project involves the design, modelling and manufacturing of helical gears in
marine applications. It is proposed to focus on reduction of weight and producing high
accuracygears.
Key words: Gear design,Computer aided analysis, Gear hobbing, Gear shaving, Structural
analysis
1.Introduction
Agearisarotatingmachineparthavingcutteeth,whichmeshwithanothertoothedpartin
ordertotransmittorque.Twoormoregearsworkingintandemarecalledatransmissionand
can produce a mechanical advantage through a gear ratio and thus may be considered a
simplemachine.Geareddevicescanchangethespeed,magnitude,anddirectionofapower
source.Themostcommonsituationisforageartomeshwithanother gearhoweveragear
can also mesh with a nonrotating toothedpart, called arack, thereby producing translation
insteadofrotation.The gears inatransmissionareanalogoustothewheels inapulley.An
advantage of gears is that the teeth of a gear prevent slipping. When two gears of unequal
numberofteetharecombined,amechanicaladvantageisproduced,withboththerotational
speeds and the torques of the two gears differing in a simple relationship. In transmissions
which offer multiple gear ratios, such as bicycles and cars, the term gear, as in first gear,
referstoagearratioratherthananactualphysicalgear.Thetermisusedtodescribesimilar
devicesevenwhengearratioiscontinuousratherthandiscrete,orwhenthedevicedoesnot
actuallycontainanygears,asinacontinuouslyvariabletransmission.
2.DesignMethodology
Inordertodesignahelicalgearsystemthefollowingprocedureshouldbefollowedtheinput
conditionsarepower,speed,helixangle,gearratio.

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Step:1 Geardesignstartswithmaterialselection.Propermaterialselectionisveryimportant
aluminiumhasbeenselectedasamaterial.Ifthematerialforgearandpinionissamethenthe
designshouldbebasedsinceitisweak.
Step:2 Findouttheminimumcentraldistancebasedonthesurfacecompressionstressis
a(i+1)3(0.7/c)2E(Mt)i.[Designdata]
HereMt=torquetransmittedbythepinion=97420(KW/N)*Kd*K
WhereKd*K=1.3,=b/a..[Designdata]
Step:3 Minimumnormalmodulesmayedeterminedas
mn1.15Cos{Mt/YvbmZ1}^1/3..[designdata]
AssumeZ1=18,m=b/mn=10from..[designdata]
VirtualnumberofteethZv=Z1/cos3,
LewisformfactorYv=0.1540.192/Zv.[Designdata]
NumberofteethonpinionZ1=2acos/mn*(i+1),NumberofteethongearZ2=iZ1
DiameterofpinionD1=mn*Z1/cos,DiameterofgearD2=mn*Z2/cos
Centredistancea=D1+D2/2,Facewidthb=a
Step:4 checkingthecalculations:
a):basedonthecompressivestress,c=0.7(i+1)/a*{(i+1/ib)*E[mt]}
b):basedonthebendingstress,b=0.7(i+1)(Mt)/{a.b.mn.Yv}
Herethebendingandcompressivestressvaluesobtainedarelessthanthematerialproperty
values,thenthedesignissafe
2.1Theoreticaldesigncalculation
Thetheoreticaldesigncalculationsareperformedusingthe inputparameterssuchaspower
for marine high speed engine, pinion speed, gear ratio, helix angle, pressure angle etc. i.e
Power P=9000 KW, Speedof Pinion N =3500 rpm, Gear Ratio i=7, HelixAngle, =
25oMinimumcentredistancebasedonsurfacecompressionstrengthisgivenby
2

0.7
E[M t ]
a ( 7 + 1)
x
iy
sc
3

[Table8PSG]

2.2MaterialSelection
LetthematerialforPinion&GearisAluminumAlloy
Itsdesigncompressivestress&bendingstressesare[c=25000kgf/cm2],[b=3500
kgf/cm2][12]
2.2MaterialSelection
LetthematerialforPinion&GearisAluminumAlloy

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Its design compressive stress & bending stresses are [c = 25000 kgf/cm2], [b = 3500
kgf/cm2][15]
2.2.1PropertiesforAluminumAlloy
DensityofAluminumAlloy()=3900kg/m3
YoungsModulus=340x103 N/mm2PoissonsRatio(v)=0.220
i=7,=b/a,=0.3,[MT]=MTkdk,MT=97420KW/N,kdk=1.3[15]
[MT]=MTkDk=(97420x9000x1.3)/3500=325661.14kgfcm
Now,minimumcentredistancebasedonthesurfacecompressivestrengthisgivenby
0.7
(i+ 1)x3 xE[Mt ]
sc
a
(iy )
a>27.66cm=28cm
Minimummodulebasedonbeamstrength:
[Mt ]
Mn>1.15cosx3Yvsby mZ1
[Table8,PSG]
LetZ1=18,m=10,VirtualnumberofteethZv=Z1/cos2 =18/0.744=25from[Table
11,PSG designdatabook]
LewisformfactorYv(forZv=25)=0.4205
[325661.14]
mn>1.15cos25x30.4205x3500x10x18
mn>1.11cm,mn>11.16mm,Butformn=1116mm,candbare>[c]&[b]also
FS<FD
whichmakesdesignunsafe.
Somn=18mm=1.8cm
2acosb
= 3.5
No.ofteethofpinion,Z1= mn (i+1)

Butinordertoavoidinterference,Ztistakenas18,No.ofteethongear,Z2=iZ1=126
mn
1.8
xZ1 =
x18= 35.74cm
cos25
Diameterofthepinion(d1)= cosb
Diameterofthegear(d2)= id1=7x35.74=250.2cm
d1 +d2
= 142.99cm
Centredistance(a)= 2
Facewidthb=.a=0.3x142.99=42.899cm

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CheckingCalculations:
i +1 i+ 1
xE[Mt] [s c]
ib
c=0.7x a
i +1
[Mt] [s c]
b=0.7x abMnYv

BasedontheCompressiveStresses
i +1 (i+ 1)xEx[MT ]
a
(ib) [s c]
c= 0.7x
(i +1)x[MT ]
[s b]
b= 0.7x (abxmxnxYv)
Basedonthecompressivestress
0.7x8x325661.14
=150.303N /mm2
143
*
43
*
1
.
8
*
0
.
4205
c=
Basedonbendingstressb =220.35N/mm2
Fromthecalculations,candbare>[c]&[b]valuesofgivenmaterial,
i.e.,Aluminumalloy[98%Al2O3,0.40.7%Mn,0.40.7&Mg].Thereforeourdesignissafe.
Addendum,mn=18mm,Dedendum=1.25xmn=22.5mm,
Tipcirclediameterofthepinion=d1+(2xaddendum)=357.4+36=393.4mm
Tipcirclediameterofgear=d2+(2xaddendum)=2502.4+36=2538.46mm
Rootcirclediameterofpinion=d1 (2xaddendum)=357.4 36=321.4mm
Rootcirclediameterofgear=d2 (2xaddendum)=2502.4 36=2466.4mm
WhenthegeartransmitsthepowerP,thetangentialforceproducedduetothepowerisgiven
by
pxD
pxNp px357.4x3500
Pxks
V =
=
= 65.51m/s
Ft =
v ,
60 x1000
60x1000

Ft =

9000x103 x2
= 274749.26N
65.51

Lewisderivedtheequationforbeamstrengthassumingtheloadtobestaticwhenthegearis
running at high speeds the gears may be subjected to dynamic effect. To account for the
dynamiceffect,afactorCvknownasVelocityfactorordynamicfactorisconsidered.
PxksxCv
V
Thedesigntangentialforcealongwithdynamiceffectisgivenby
The velocity factorCv is developedby Barth. It dependson the pitch line velocity and the
workmanshipinthemanufactureandisgivenby
5.5+ V
Cv =
5.5
FD = FtxCv =

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ForV>20m/s,WhereFT=274749.26N,Ks =2,V=65.5m/s
5.5+ 65.51
Cv =
= 2.47
5.5
FD=274749.26x2.4=679084.7315N,
AccordingtoLewisequation,thebeamstrengthofhelicalgeartoothisgivenby
FS=[b].b..mn.yvandFS=(3500)x42.8xx18x0.4205=3570318.5N
Since,FS>FD,Ourdesignissafe.
Whenthepoweristransmittedthroughgears,apartfromstatic(steady)loadproducedbythe
power,somedynamicloadsarealsoappliedonthegeartoothduetoreasonslikeinaccuracies
of tooth profiles and deflections of tooth under load. Considering the above conditions
Buckinghamderivedequationtofindoutthemaximumloadactingonthegeartoothandis
givenbyFD=Ft+Fi,WhereFd=Maximumdynamicload,Ft=Staticloadproducedbythe
power,Fi=Incrementalloadduetodynamicaction,Incrementalloaddependsonthepitch
line velocity, face width, of a gear tooth, gear materials, accuracyof cut and the tangential
loadandisgivenby
0.164Vm(cbcos2 b + Ft)Cosb
Fi =
0.164Vm + 1.485 cbcos2 b + Ft
where,Vm=Pitchlinevelocityinm/s,b=Facewidthofthegeartoothinmm
C=Dynamicfactor(or)DeformationfactorinN/mm.DeformationfactorC,[15]
Here,C=11860xe,C=11860x0.026,=308.36N/mm
Ft=137572.60N,m=65.51x103mm/sec,b=428.9mm,=250 Fd=Ft+Fi
0.164Vm(cbcos2 b + Ft)Cosb
Fd = Ft +
0.164Vm + 1.485 cbcos2 b + Ft
1540999543
Fd = 274749.26+
= 273754.19N
11315.76937
SinceFs>Fd,ourdesignissafe.
One of the most predominant gear failures is the failure of gear tooth due to pitting. This
pitting failure occurs when the contact stresses between the two meshing teeth exceed the
surface endurance strength of the material. In order to avoid this type of failure the
proportions of gear tooth and the surface properties such as surface hardness should be
selectedinsuchawaythatthewearstrengthofthegeartoothismorethantheeffectiveload
betweenthemeshingteeth.
BasedonHertztheoryofcontactstresses,Buckinghamderivedanequationforwearstrength
ofgeartoothwhichisgivenby
Fw=

d 1 .b.Q.Kw
cos 2 b

whereFw=MaxorlimitingloadforwearinNewtons

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d1=pitchcirclediameterofpinioninmm,b=Facewidthofthepinioninmm,Q=Ratio
2i
= 1 .75
factor= ( i + 1 )
Kw=2.553N/mm2
[Table25.37JDB]
d1 =357.4mm,
b=428.9mm
685180.942
8
d .b.Q.Kw
=834168.62N
2
cos b
Fw=
= cos 25
Fd=273754.19NsinceFw>Fdourdesigninsafe.
1

3.Modelling
AmodelisgeneratedusingCATIAsoftwareandthenitisretrievedintoANSYSusingIGES
files.HelicalGearteethasshowninfig:1

Figure1:ImageshowingthemodelpreparedinCATIA
Acompletehelicalgearisobtainedasshowninfigure 2

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Figure2:Imageshowingthedesignedhelicalgear

3.1Analysis
SignificantDevelopmentinanalysisofstrengthpropertiesofgeartransmissionfollowsthe
achievementsincomputationdesign,simulationofmeshingandtoothcontactanalysismade
by Lewiki,Handschuh.They carried out 2D analyses using finite element method, boundary
element methods&Comparedtheresultstoexperimentalones validatedcracksimulation
based on calculated stress intensity factors and mixed mode crack angle prediction. In
practice, simplified formulas are usually used in gear transmission design. They enables
estimationofstressesattoothrootwithaccuracyacceptableforengineeringdesign.Inevery
case, strength properties of gear transmissions are strongly influenced by gear geometry,
appliedmanufacturingprocesses,anddimensionalaccuracyofmanufacturedgears.
3.2GearManufacturing
Gearsaremanufacturedbyvariousprocesses.Theseare,casting,stamping,rolling,extruding,
and machining. Gears can also be produced by powder metallurgy. Among the above said
process,machiningprocessinmostcommonlyused.Itisanaccuratemethod.Basicallygears
areproducedbymachiningbya)Formingmethod.b)Generatingmethod.
3.2.1FormingMethod
Inthismethodaformcutterisused.Theformedcuttermaybesinglepointcuttingtoolora
multipoint milling cutter. The cutting edges formed cutter has been finished to the shape
betweenthegearteethbeingcut.Formingmethodisusedforproducingvery smallnumber
ofgears.Gearsproducedbyformingarelessaccurate.Formingprocessissimpleandcheaper.
Thismethodistakesmoretime.
3.2.2GearGeneratingProcess
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This methodof gear manufacturing is based on the fact that any two involute gears of the
same module will mesh together. Here oneof the meshing gears is made asthecutter. The
other gear rotates and also reciprocates along the width of the gear blank. Because of the
relative rolling motion between cutter and the blank, gear teeth are generated on the gear
blank.Thegearmaybegeneratedbyrackcutter,pinioncutterorahob.Usingthegenerated
method,profileofthegearteethcanbeveryaccuratelyproduced.Thefollowinggenerating
methodsusedforgearproductionareGearshaping,Gearplanning,Gearhobbing.
3.2.3GearHobbing
It is a process of generating a gear by means of a rotating cutter called hob. The hob has
helicalthreads.Groovesarecutinthethreadsparalleltotheaxis.Thiswillprovidetheedges.
Properrakeandclearanceanglearegroundonthesecuttingedges.Therotatinghobactslike
acontinuouslymovingrackasitcuts.Theblankismountedonaverticalarbour.Thehobis
mounted in a rotating arbour. The hob axis is tilted the hob lead angle so that its teeth are
paralleltotheaxisofthegearblank.

Then=(901).Where1=helixangleofthehobthread.NOTE:(hobleadangle=90hob
helixangle)
Thehobisrotatedatsuitablecuttingspeed.Itisfedacrosstheblankface.Thehobandblank
are made to rotate in correct relationship to each other they rotate like a worm and worm
gear inmesh.Foronerelationofthehob,theblankrotatesbyonetooth.(Incaseofsingle
starthob).
Forhelicalgears,theaxisofthehobisinclinedtohorizontally.Where a=+(901).(Ifthe
helixofthehobandthehelixofthegeartobecutaredifferent.Oneisrightandanotheris
lefthanded.)
a=(901)(ifthehelixofthehobandthehelixofthegeartobecutarebothrighthanded
orbothislefthanded.)
Where, a =helixangleofthehelicalgeartobecut.,1=helixangleofthehob.
The gear hobbing technique is used for generating spur, helical and worm gears. Gear
hobbingisusedinautomobiles,machinetools,variouscomponents,instruments,clocksand
otherequipment.
In the present the helical gears were produced by gear hobbing technique and finished by
gearshavingoperation.
Thegearteethgeneratingprocessbymillingmachineisshowninfig3

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Figure3:Imageshowingmillingmachine
Thegearteethgeneratingprocessbyhobbingprocessisshownfigure4

Figure4:Imageshowingthehobbingprocess
Thegearfinishingprocessisshowninthefigure5

Figure5:Imageshowingthegearfinishingprocess

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3.2.4 FinishingProcess
Gears manufactured by different machining processes will have rough surfaces. The
machined gears may have errors in tooth profiles, concentricity and helix angles. For quiet
and smooth running of gears, these errors and rough surfaces should be removed. Gear
finishingoperationsaredoneforthispurpose.Thevariousgearfinishingprocesseslikegear
burnishing,gearshavingetc.
3.2.5 GearBurnishing
Isamethodoffinishingofgearteethwhicharenothardened.Thisisacoldworkingprocess.
This method is used to improve the surface finish of the gear teeth. This also increases the
hardness at the teeth surface. The teeth of burnishing gears are very hard, smooth and
accurate.They arearrangedat120positionaroundtheworkgear.Thegearsarerotatedin
one direction for some period. Then they are rotated in the reverse direction for the some
period.Thepressureisappliedbytheharderburnishingteethontheworkgear.
3.2.6 GearShaving
Thisisthemostcommonmethodofgearfinishing.Inthismethodaveryhardgearshaving
cutterisusedtoremovefinechipsfromthegearteeth.Theshavingcuttermaybeintheform
ofarackorapinion.Therotarymethodusingpinioncutterisusedonalltypesofgears.The
rotating cutter will have helical teeth of about 15 helix angle. The cutter has a number of
serrationsonitsperiphery.Theseactascuttingedges.Intherotarytypeofgearshavingthe
workgear is heldbetweencentresandisfreetorotate.Theshavingcuttermeshes withthe
workgear.Theaxisofthecutterisinclinedtothegearatanangleequaltothehelixangleof
thecutter()whenthecutterrotate,thecutterreciprocatesinadirectionparalleltothegear
axis. The cutting edges of the shaving cutter remove burrs, nicks and high points on the
surfaceoftheworkgear.Itcanremovefromtheteethflank,chipsupto0.1mmthick.

4. Resultsanddiscussions
TheoreticaldesigniscarriedoutusingstandarddesignformulaeasperAGMAprocedureand
carriedoutanalysesby ANSYSandanalysiscarriedoutusingANSYS.Thefollowingtable.1
showsthecomparisonthetheoreticaldesignvalueswithANSYSvalues.
Table1. Comparison oftheoreticalandANSYSdesignvalues
S.No Parameter

Designvalues

Ansysvalues

Bendingstress

220.35N/mm2

205.576N/mm2

Compressive
stress

150.303N/mm2

139.076/mm2

Vonmisses
stress

2000N/mm2

260.92N/mm2

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Deflection

0.058752mm

From the table.1, it is observed that the bending stress, compressive stress, vonmisses
stressesofANSYSvaluesarelessthanthedesignvalues.Hencethedesignissafe.Thenthe
gearsaremanufacturedusinggearhobbingtechniqueandfinishedbygearshavingoperation.
5.Conclusions
1. Bending, compressive, Vonmisses stresses were obtained by theoretical and Ansys
software for Aluminum alloy. The obtained stresses by ANSYS are less than that of the
theoreticalcalculations.
2. From the results, it is observed that the bending and compressive stresses of aluminum
alloy(ceramics)arelessthanthatoftheothermateriallikesteel.
3.Aluminumalloyreducestheweightupto5567%comparestotheothermaterials
4. Aluminum is having unique property (i.e. corrosive resistance), good surface finishing,
henceitpermitsexcellentsilentoperation.
5. Weight reduction is a very important criterion, in order to minimize the UN balanced
forcessetupinthemarinegearsystem,therebyimprovesthesystemperformance.
6.Hencealuminumalloyisbestsuitedformarinegearinthe highspeed applications.
7.Thedesignedgearsethavebeenmanufacturedusinggearhobbingtechniqueandfinishedby
gearshavingoperationandtestedforthestrengthofthegearteeth.

Acknowledgements
FirstauthorisgratefultoDr.T.Srinivasulu,PrincipalVCEshamshabadandDr.G.V.RaoHead
Mechanical Engineering Department for their valuable support. He is also thankful to the
management of the institute for the encouragement, support, and cooperation during the
entirework.
6.References
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TransmissionErroreffectofwheelbodydeformationandinteractionsbetweenadjacent
loadedteeth,hal 00121847,Version122Dec2006.
2. ZepingWei.,2004StressesandDeformationsinInvolutespurgearsbyFiniteElement
method,M.S,Thesis,CollegeofGraduateStudiesandresearch,UniversityofSaskatchewan,
Saskatchewan.

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3. PSG,2008,Designdata,KalaikathirAchchagampublishers,CoimbatoreIndia
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