“DESIGN AND ANALYSIS OF BEVEL

GEARS”

PROJECT REPORT
Submitted for the course: Engineering Failure Analysis

MEE3003

By

Atharva Shinde 17BME0961

Shivam Kapil 17BPI0034
Raghav Agrawal 17BPI0022
Mohammed Faizan 17BPI0080
Gaurang Dhaybhai 17BME0346

Slot: D1+TD1
Name of faculty: Prof. Sreethul Das

(SCHOOL OF MECHANICAL ENGIEERING)

ABSTRACT

The objective of this project is to appreciate the design of Bevel Gears used in the real world as
speed reducer and hand drill. Our aim is to minutely analyze the different structural nuances
associated with the overall construction of bevel gears by performing Static, Harmonic and
Dynamic Analysis on its Solid works model after studying its geometry and Performing Meshing
on Ansys R18.
INTRODUCTION
Bevel gears are gears where the axes of the two shafts intersect and the tooth-bearing faces of the
gears themselves are conically shaped. Bevel gears are most often mounted on shafts that are 90
degrees apart but can be designed to work at other angles as well. The pitch surface of bevel gears
is a cone.

The most familiar kinds of bevel gears have pitch angles of less than 90 degrees and therefore are
cone-shaped. This type of bevel gear is called external because the gear teeth point outward. The
pitch surfaces of meshed external bevel gears are coaxial with the gear shafts; the apexes of the
two surfaces are at the point of intersection of the shaft axes.

(i) Bevel gears that have pitch angles of greater than ninety degrees have teeth that point
inward and are called internal bevel gears.
(ii) Bevel gears that have pitch angles of exactly 90 degrees have teeth that point outward
parallel with the axis and resemble the points on a crown. That's why this type of bevel gear is
called a crown gear.
(iii) Mitre gears are mating bevel gears with equal numbers of teeth and with axes at right
angles.
(iv) Skew bevel gears are those for which the corresponding crown gear has teeth that are
straight and oblique.

Bevel gears are classified in different types according to geometry:

Straight bevel gears have conical pitch surface and teeth are straight and tapering towards apex.

Spiral bevel gears have curved teeth at an angle allowing tooth contact to be gradual and smooth.

Zero bevel gears are very similar to a bevel gear only exception is the teeth are curved: the ends
of each tooth are coplanar with the axis, but the middle of each tooth is swept circumferentially
around the gear. Zero bevel gears can be thought of as spiral bevel gears, which also have curved
teeth, but with a spiral angle of zero, so the ends of the teeth align with the axis.

Hypoid bevel gears are similar to spiral bevel but the pitch surfaces are hyperbolic and not
conical. Pinion can be offset above, or below the gear center, thus allowing larger pinion
diameter, and longer life and smoother mesh, with additional ratios e.g., 6:1, 8:1, 10:1. In a
limiting case of making the "bevel" surface parallel with the axis of rotation, this configuration
resembles a worm drive. Hypoid gears were widely used in automobile rear axles.

Bevel Gears find their application in differential drives, hand drill, bevel gear planer and
rotorcraft
EXPERIMETAL STRUCTURAL ANALYSIS-
The following was the modus operandi while analyzing the design

Geometry:
Shows the axes of the two shafts intersect and the tooth bearing faces of the gears themselves are
conically shaped mounted 90 degrees apart. The following model has been designed and imported
from SolidWorks 2016

Meshing:
Basically defining the model imported from Solid works 2016 , further steps in line to be carried
out
Fig- Main Menu snapshot of applied processes in Ansys R18.2

As per the requirements , the gear structure was analyzed in 3 sectors

( Static , Harmonic and Dynamic Analysis ) and Von Mises Stress was also
determined.
The materials for the gear system used are
1. 300 series Stainless Steel
2. A-286 Steel
3. Aluminum Silicon Carbide Composite
1) STATIC ANALYSIS:
a) Model set up:

b) Total Deformation:

i) 300 Series Stainless Steel:

ii) A-286 Steel

iii) Aluminum Silicon Carbide Composite

c) Equivalent (von-Mises) Stress
i) 300 series stainless steel

ii) A-286
iii)Al-SiC
2) HARMONIC ANALYSIS:
a) Model Set up:

b) Total Deformation (Frequency – Hz):

i) 300 series stainless steel
ii) A-286 Steel

iii) Al-SiC
DYNAMIC ANALYSIS:

a) Model Set-up:

b) Total Deformation

i) 300 Series Stainless Steel:

ii) A-286 Steel:

iii) Al-SiC:
CONCLUSION-
Determining Parameters such as Torque, Applied forces and Total deformation in Static,
Harmonic and Dynamic Analysis Case is different due to different materials used. All materials
have different physical and mechanical properties owing to their different chemical compositions.

After analysis of these parameters it can be concluded that the Aluminum silicon carbide
composite is a better-suited material than 300 Series stainless steel and A286 Steel, for spur gears.