INTERNATIONAL JOURNAL

OF PROFESSIONAL ENGINEERING STUDIES Volume VIII /Issue 2 / JAN 2017

DESIGN AND ANALYSIS OF RACK GEAR MECHANICAL DRIVE

1
SK . PARVEENSULTANA, 2 HASEENA BEE
1
Pg Scholar, Department of MECH, Mallareddy College Of Engineering And Technology, maisammaguda
,Dhulapally post,secunderabad-500100
2
Assistant Professor, Department of MECH, Mallareddy College Of Engineering And Technology, maisammaguda
,Dhulapally post,secunderabad-500100

ABSTRACT also the axis of rotation. For high speed machinery,

This project Rack and pinion gears are used such as an automobile transmission, they are the
to convert rotation into linear motion. The flat, optimal medium for low energy loss and high
toothed part is the rack and the gear is the pinion. A accuracy.
piston coaxial to the rack provides hydraulic Their function is to convert input provided
assistance force, and an open centered rotary valve by prime mover into an output with lower speed and
controls the assist level. A rack and pinion gears corresponding higher torque. Toothed gears are used
system is composed of two gears. The normal round to transmit the power with high velocity ratio. During
gear is the pinion gear and the straight or flat gear is this phase, they encounter high stress at the point of
the rack. The rack has teeth cut into it and they mesh contact.
with the teeth of the pinion gear. A ring and pinion
gear is the differential's critical point of power Purpose
Gearing is one of the most critical components in
transfer. A ring and pinion gear set is one of the
mechanical power transmission systems. The transfer
simplest performance modifications that can be
of power between gears takes place at the contact
performed on a vehicle. In this project the component
between the mating teeth. During operation, meshed
is deign and modeled in one of the 3d software called
gears‟ teeth flanks are submitted to high contact
catia, the individual components like gear and shafts
pressures and due to the repeated stresses, damage on
are design in part module and assembled in assembly
the teeth flanks, in addition to tooth breakage at the
module. Later the component is imported in most
root of the tooth are one of the most frequent causes
advanced analysis software called ansys. In this
of gear failure.
project the component is under go to model analysis
and static structural analysis to find out the stress and
Law Of Gearing
deformation of product in applied pressure or
A primary requirement of gears is the constancy of
momentum.
angular velocities or proportionality of position
transmission.
Introduction
Gearing as follows:
Gears are used for a wide range of industrial
"A common normal to the tooth profiles at their point
applications. They have varied application starting
of contact must, in all positions of the contacting
from textile looms to aviation industries. They are the
teeth, pass through a fixed point on the line-of-
most common means of transmitting power. They
centers called the pitch point."
change the rate of rotation of machinery shaft and

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 INTERNATIONAL JOURNAL
OF PROFESSIONAL ENGINEERING STUDIES
Rack And Gear
A rack is a toothed bar or rod that can be thought of
as a sector gear with an infinitely large radius of
curvature. Torque can be converted to linear force by
meshing a rack with a pinion: the pinion turns; the
rack moves in a straight line. Such a mechanism is
used in automobiles to convert the rotation of
the steering wheel into the left-to-right motion of the
tie rod(s).
A rack and pinion is a type of linear
actuator that comprises a pair of gears which convert
rotational motion into linear motion. A circular gear
called "the pinion" engages teeth on a linear "gear"
bar called "the rack"; rotational motion applied to the
pinion causes the rack to move relative to the pinion,
thereby translating the rotational motion of the pinion
into linear motion.
Fig: rack and gear
Applications
Rack and pinion combinations are often
used as part of a simple linear actuator, where the
rotation of a shaft powered by hand or by a motor is
converted to linear motion.
The rack carries the full load of the actuator
directly and so the driving pinion is usually small, so
that the gear ratio reduces the torque required. This
force, thus torque, may still be substantial and so it is
common for there to be a reduction gear immediately
before this by either a gear or worm gear reduction.
Rack gears have a higher ratio, thus require a greater
driving torque, than screw actuators.
Stair lifts
IJPRES
Volume VIII /Issue 2 / JAN 2017
Most Stair lifts today are operating using the
Rack & Pinion system.
Advantages and Disadvantages
Advantages
 Cheap
 Compact
 Robust
 Easiest way to convert rotation motion into linear
motion
 Rack and pinion gives easier and more compact
control over the vehicle
Disadvantages
The rack and pinion can only work with certain levels
of friction. Too high a friction and the mechanism
will be subject to wear more than usual and will
require more force to operate.
Literature Survey
s.kramer the rack and gear mechanism is synthesized
for generating four prescribed path points with input
coordination. This mechanism has a number of
advantages over the well-known four-bar linkage.
First, the transmission angle is always at its optimum
value of 90 deg since the rack is always tangent to the
gear. Second, with both translation and rotation of the
rack occurring, multiple outputs are available
Introduction CATIAV5R20
CATIA is the leading solution for product
success. It addresses all manufacturing organizations.
CATIA can be applied to a wide variety of industries-
from aerospace- automotive- and industrial
machinery- to electronics- shipbuilding- plant design-
and consumer goods. Today- CATIA is used to
design anything from an airplane to jewelry and
clothing.
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 INTERNATIONAL JOURNAL
OF PROFESSIONAL ENGINEERING STUDIES Volume VIII /Issue 2 / JAN 2017

Modeling Of Rack Gear Assembly

Part 1: Base

Assembly

Part 2: Holder Plate

Part 3: Sliding Gear Rod Assembling parts after modification

Introduction To Fem And Ansys

Part 4: Gear Introduction To Fem
The finite element method represents an extension of
the matrix methods for the analysis of framed
structures to the analysis of the continuum structures.
The basic philosophy of the method is to replace the
structure of the continuum having an unlimited or
infinite number of unknowns at certain chosen
discrete points. The method is extremely powerful as
it helps to accurately analyze structures with complex
geometrical properties and loading conditions.
Introduction To Ansys Software
The purpose of a finite element analysis is to

Part 5: Gear Hand (Before Modification)
model the behavior of a structure under a system of
loads. In order to do so, all influencing factors must
be considered and determined whether their effects
are considerable or negligible on the final result.
The ansys program is self-contained general
purpose finite element program developed and
maintained by swanson analysis systems inc. The

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 INTERNATIONAL JOURNAL
OF PROFESSIONAL ENGINEERING STUDIES Volume VIII /Issue 2 / JAN 2017

program contains many routines, all interrelated and For Different Frequencies Go To Different
all for main purpose of achieving a solution to an Deformation
engineering problem by finite element method.
MODAL ANALYSIS:
After importing the model into project schematic
window drag and drop the modal tab on to the screen
from the toolbox window and link the geometry to
geometry both will be linked together. Double click
on the model it opens the mechanical window with
object
Meshing:
The default meshing controls that the program
uses may produce a mesh that is adequate for the
STATIC STRUCTURAL ANALYSIS (BEFORE
model we are analyzing. In this case, we need not
MODIFICATION)
specify any meshing controls. However if we do use
Fixed support and pressure
meshing controls we must set them before meshing
To fix the component: right click on the
the solid model.Meshing controls allow us to
analysis settings – insert – fixed support – select all
establish the element shape, midsize node placement
the bushes or bearings location and apply.
and element size to be used in meshing the solid
To pressure the component: right click on
model, this step is one of the most important of the
the analysis settings – insert – pressure – on pressure
entire analysis for the decisions we make at this stage
definitions specify 1mpa (106 Pascal) and selects face
in the model development will profoundly affect the
pressure is applied because of body with is going to
accuracy and economy of the analysis.
fix it.

Solution
Total deformation Solution
Total deformation

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 INTERNATIONAL JOURNAL
OF PROFESSIONAL ENGINEERING STUDIES Volume VIII /Issue 2 / JAN 2017

Equivalent stress Material data

Grey cast iron

STATIC STRUCTURAL ANALYSIS (AFTER

MODIFICATION)
Fixed support and pressure

Total component properties

Total Deformation

Individual body properties before modification

Equivalent Stress

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 INTERNATIONAL JOURNAL
OF PROFESSIONAL ENGINEERING STUDIES Volume VIII /Issue 2 / JAN 2017

Individual body properties after modification CONCLUSION

1. In this project modeling and assemble of a
rack gear mechanism is carried out. The rack
gear mechanism is modeled with the help of
catia v5 software by using dimension.
2. And the individual component are upload
into assemble module by using top down
assembly. By using assembly modules the
components are assembled together to form
a rack gear assembly.
3. Later by using dmu kinematics the
simulation is created.
Results: 4. Later the file is saved in the format as a STP
Model analysis or IGES file to do analysis on the
component.
5. The analysis is done by ansys software one
of the most practical meshing accurate
analysis software to find out the results over
the component.
6. The Model weight was reduced after
modification from 11.622 kg to 11.531 kg at
a density of 7.2e-006 kg mm^-3.
7. The stress value was reduced from 126.17
Mpa to 125.34 Mpa.
8. From the above results it is suggest that the
Static structural analysis design modification was acceptable.

At pressure 1 Mpa (106) References

Claudio, M., and Kramer, S., 1986, "Synthesis and
Analysis of Rack and Gear Mechanism for Four
Point Path Generation with Prescribed Input Timing,"
ASME JOURNAL OF MECHANISMS,
TRANSMISSIONS, AND AUTOMATION IN
DESIGN, Vol. 108, No. 1, pp. 10-14.
Duschl, P., and Kramer, S., 1987, "Kinematic
Synthesis and Analysis of the Rack and Pinion
Mechanism for Six Precision Conditions," Mech.
Mach. Theory, Vol. 22, No. 6, pp. 563-568.

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OF PROFESSIONAL ENGINEERING STUDIES Volume VIII /Issue 2 / JAN 2017

Gibson, D., and Kramer, S., 1984, "Kinematic AUTHORS

Design and Analysis of the Rack and Gear 1. SK.PARVEENSULTANA
Mechanism for Function Generation," Mech. Mach. M.Tech, Mechindesign(2013-2015 Batch)
Theory, Vol. 19, No. 3, pp. 369-375. Department Of Mech
Hof meister, K. E., and Kramer, S. N., 1984, Malla Reddy College Of Engineering And
"Kinematic Synthesis, Analysis and Optimization by Technology,
Precision Point Re spacing of the Function Maisammaguda, Dhulapally Post,Secunderabad-
Generating Mechanism," ASME Mech. Con/., Paper 500100
No. DET-134. Email Id: Parveensultana.Shaik345@Gmail.Com
Kinzel, G. K., and Chen, S., 1984, "A General
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