International Journal of Mechanical

INTERNATIONAL JOURNAL Engineering and Technology (IJMET),

OF MECHANICAL ISSN 0976 – 6340(Print),
ENGINEERING AND
ISSN 0976 – 6359(Online), Volume 6, Issue 4, April (2015), pp. 117-125© IAEME
TECHNOLOGY (IJMET)

ISSN 0976 – 6340 (Print)

ISSN 0976 – 6359 (Online) IJMET
Volume 6, Issue 4, April (2015), pp. 117-125
© IAEME: www.iaeme.com/IJMET.asp
Journal Impact Factor (2015): 8.8293 (Calculated by GISI) ©IAEME
www.jifactor.com

COMPARATIVE FINITE ELEMENT ANALYSIS OF

METALLIC SPUR GEAR AND HYBRID SPUR GEAR

Sanjay K. Khavdu1, Prof. Kevin M. Vyas2

1
M.E. CAD/CAM, Noble Group of Institute, Junagadh, Gujarat
2
Mechanical Department, Noble Group of Institute, Junagadh, Gujarat

ABSTRACT

Gear is the special division of Mechanical Engineering concerned with the transmission of
power and motion between the rotating shafts. In this study, a lathe machine tumbler gear mechanism
used for threading purpose is taken and applied finite element analysis methodology on each metallic
spur gears and also FEA analysis is done for hybrid spur gear with same applied load and condition to
check comparative stress analysis of both metallic spur gears and hybrid spur gears.
Main purpose of this study is to reduce weight of this gear mechanism by checking possibility
of replacement of all metallic gears with composite hybrid gears in that gear mechanism. And a weight
calculation is done using ANSYS workbench v11.

Keywords: AGMA Stress, Bending Stress, FEM, HYBRID GEAR, Spur Gear, Tumbler Gear
Mechanism.

1. INTRODUCTION

Gears are the most useful and common means of transmitting motion and power in the today
modern engineering field. They vary from tiny size used in watches to the large gears used in the lifting
devices and speed reducers. Gears are the valuable mechanical element of mechanism such as rolling
machinery, metal cutting machinery and automotive machinery.
There are different materials used as a gear material. Gear materials are used as per the type of
application of power transmission and loading condition. All material are not providing similar
properties during working condition due to their different structure and bonding nature. Materials are
to be required to check under loading conditions to find their beneficial properties and remove
unnecessary properties during the selection of material. When gears are in a loading condition, mainly
two types of failure are produced in gear material like as bending failure due to low bending strength of
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 6, Issue 4, April (2015), pp. 117-125© IAEME

material and pitting or contact failure due to lower strength of contact area of gear teeth.
For analysis purpose of spur gears, “Lathe Machine Tumbler Gear Mechanism” is selected for
material analysis.

1.1 Objectives of The Work

Check comparative stress in conventional metallic material of spur gears using a static finite
element method.
Check stress analysis for hybrid gear using static finite element analysis.
Weight reduction of a lathe machine gear mechanism.

1.2 Specification of Gear Mechanism

Figure-1.1:- Lathe machine gear mechanism

Table-1.1:- Lathe Machine Specification

Manufacture
Natraj Brand
Name
2 HP, 3PH, 1440
Electric motor
rpm
Gear type Parallel spur gear
Pressure angle 200
Module 2
Cast
Material
Iron-SG700/2

There are eight gears in this gear mechanism and minimum speed of first input gear A is 200
rpm that I have measured with digital tachometer.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 6, Issue 4, April (2015), pp. 117-125© IAEME

Table-1.2:- Gear Parameter

GEAR NUMBER
OUTSIDE DIA. P.C.D
NAME OF TEETH
A 44 92 88
B 25 54 50
C 25 54 50
D 33 70 66
E 30 64 60
F 100 204 200
G 55 114 110
H 127 258 254

Figure-1.2:- Modeling of Lathe Gear Mechanism

2. DESIGN CALCULATION

2.1 Material Data

Table-2.1:-Material Data [9]
Material Cast Iron(Ductile)-SG700/2
Compressive Tensile
Young's Modulus
Density Ultimate Strength Ultimate Poisson's Ratio
MPa
MPa Strength MPa
7300
840 700 35000 0.28
kg/m3
Chemical Composition
Carbon Manganese Silicon Phosphorous Sulphur Magnesium
3.40 - 3.85 % 0.10 – 0.30 % 2.30 – 3.10 % 0.10 % 0.02 % 0.07

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 6, Issue 4, April (2015), pp. 117-125©
© IAEME

2.2 Design Input for Gear “A”

Table
Table-2.2:- Input Parameters Gear A
Power 1492 watt
Pitch circle diameter 88 mm
Module 2 mm
Gear Rpm 200
No. of teeth 44

Input power:

TA = 71273.88 N.mm
Tangential force:

= 1619.86 N
AGMA Stress

= 126.55 MPa

Table
Table-2.3:- Gear Calculation Data
stress
Gear Tangential Torque
(AGMA)
Name force (Wt ) N N.mm
(Mpa)
A 1619.86 71273.88 126.55
B 1619.86 40496.52 126.55
C 1619.86 40496.52 146.72
D 1619.86 53456.75 142.59
E 1781.89 53456.75 150.49
F 1781.84 178184.71 150.49
G 3239.72 178184.71 204.48
H 3206.92 407279.34 202.39

3. HYBRID GEAR

Figure shows the hybrid gear in which there are 5 components metallic teeth ring and
metallic hub, hexagonal web and two outer composites as shown in figure. Teeth ring and hub are of
conventional metallic material cast iron while hexagonal web and outer composites are made of
triaxial braided material.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),
ISSN 0976 – 6359(Online), Volume 6, Issue 4, April (2015), pp. 117-125© IAEME

Figure-3.1:- Modeling of Hybrid Gear

Figure-3.2:- Exploded View of Hybrid Gear

The composite portion of the hybrid gear was fabricated using a tri-axial braid prepreg (Note:
A fibrous material pre-impregnated with a particular synthetic resin, used in making reinforced
plastics) material made with T700SC 12K carbon fiber tows and a 350°F epoxy matrix material.

Table-3.1:- Material Property for Hybrid Gear [2]

Triaxial Braided Composite
Material Properties Cast iron-SG700/2
Material
Hexagonal Web and Outer
Components Teeth Ring and Hub
Composites
Density 7300 kg/m3 1800 kg/m3
Ultimate Tensile
700 Mpa 833 Mpa
strength
Compressive strength 840 Mpa 395.48 Mpa
Poission’s Ratio 0.28 0.3

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ISSN 0976 – 6359(Online), Volume 6, Issue 4, April (2015), pp. 117-125© IAEME

There are other reasons for using a hybrid of composite and metallic elements in a gear. For
example, gear meshing vibration and noise should benefit from this configuration

3.1 Hybrid Gear Dimension

Figure-3.3:- Hub Figure-3.4:- Hexagonal Web

Figure-3.5:- Teeth Ring Figure-3.6:- Outer Composite

Some dimension for hybrid gears are assumed and are as below.

Table-3.2:- Hybrid Gear Dimensions

GEAR P.C.D. h Lh Lw Do
A 88 20 18 36 76
B 50 20 15 20 44
C 50 20 15 20 44
D 66 20 16 26 56
E 60 20 15 24 52
g 100 20 18 40 84

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ISSN 0976 – 6359(Online), Volume 6, Issue 4, April (2015), pp. 117-125© IAEME

3.2 Weight Calculation

Weight calculation of gears are done using ANSYS workbench v11

Table-3.3:- Weight Calculation and % Reduction

Cast Iron Gear Hybrid Gear %
Gear
kg N kg N Reduction
A 0.83755 8.2163 0.64378 6.3154 23
B 0.25725 2.5236 0.21644 2.1232 16
C 0.25725 2.5236 0.21644 2.1232 16
D 0.46986 4.6096 0.37527 3.6813 20
E 0.38279 3.7551 0.30036 2.9465 21
F 2.9149 28.595 2.9149 28.5951 -
G 1.3229 12.977 0.82038 8.0479 38
H 5.0876 49.909 5.0876 49.909 -

There is no need to make hybrid gear of gear F and G because they are already weight
reduced. From the above table we can conclude that weight of hybride gear is about 20% less than
weight of cast iron gear.

4. FEA ANALYSIS

Bending stress of spur gear teeth is generally calculated by analytically and finite element
method. Analytical bending stress is calculated by two formula Lewis formula and AGMA formula.
Analytical result is compared with the finite element method result for validation. For above purpose,
the solid model of spur gear is imported in a fem software ANSYS as an IGES file. Result of bending
stress is obtained after the meshing and boundary condition are applied on the spur gear geometry.
Nodes and element generated in meshing of gear are 26518 and 4851 respectively.
Von-Mises stress is equal to the tension stress and generally it is main cause of crack in the gear
teeth if the applied load is greater than strength of the gear teeth so gear teeth is crack from tensile
force.

Figure-4.1:- Meshing of metallic and hybrid gear AB

Metallic gear: Nodes-26518 /Element-4851(8 Node Quadratic Element)

Hybrid gear: Node-77850, Element-13485 (8 Node Quadratic Element)

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ISSN 0976 – 6359(Online), Volume 6, Issue 4, April (2015), pp. 117-125© IAEME

Figure-4.2:- Von Mises stress distribution in gear A

Figure-4.3:- Von Mises stress distribution in hybrid gear A

4.1 Comparison of FEM Result with AGMA Standard

All metallic gears of a lathe machine gear mechanism are analyzed for a stress analysis under
loading condition. And all hybrid gears are also analyzed for a stress analysis under same applied load
and condition. The study is applied in to finite element method software ANSYS V11. Here FEA
stress for metallic spur gears and hybrid spur gears are compared with AGMA stress and a table is
formed.
Table-4.1:- Comparison of AGMA and ANSYS stress
Difference (AGMA -
σ (ANSYS ) [Mpa]
GEAR σ (AGMA ) ANSYS)
NAME [Mpa] CAST IRON HYBRID CAST IRON HYBRID
GEAR GEAR GEAR GEAR
Gear A 126.55 126.79 129.90 0.18 2.65
Gear B 126.55 123.59 130.84 2.30 3.38
Gear C 146.72 144.85 148.00 1.29 0.87
Gear D 142.59 137.88 140.62 3.30 1.38
Gear E 150.49 149.08 157.23 0.94 4.47
Gear F 150.49 157.25 155.50 4.49 3.33
Gear G 204.48 195.6 209.79 4.34 2.59
Gear H 202.39 195.65 212.00 4.27 4.74

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ISSN 0976 – 6359(Online), Volume 6, Issue 4, April (2015), pp. 117-125© IAEME

5. CONCLUSION

From this research it is concluded that if we use hybrid gear instead of metallic gear then there
is a better advantage than conventional metallic gear. Main advantage of hybrid gear is that it can help
in reducing overall weight of mechanism about 20%. And also stress developed within hybrid gears
are near about stresses in metallic gears and AGMA standard stresses and within their working
strength limit. So it is advantageous for using hybrid gears in any system and mechanism where weight
reduction is desired like in aerospace drive system.

6. REFERENCES

Papers
1. Sanjay K. Khavdu, Prof. Kevin M. Vyas, April 2015, “Finite element analysis of lathe machine
tumbler gear mechanism”
2. Robert F. Handschuh, Gary D. Roberts, and Ryan R. Sinnamon, David B. Stringer, Brian D.
Dykas, Lee W. Kohlman-July 2012, “Hybrid gear preliminary results application of composites
to dynamic mechanical components”
3. Ashwini Joshi, Vijay Kumar Karma-September 2011, “Effect on Strength of Involute Spur Gear
by Changing the Fillet Radius Using FEA”
4. Pushpendra Kumar Mishra, Dr. M.S. Murthy-July 2013, “Comparison of Bending Stresses for
Different Face Width of Helical Gear Obtained Using MATLAB Simulink with AGMA and
ANSYS”
5. Gagandeep Singh, August 2014, “Increasing life of spur gears with the help of finite element
analysis”
6. M. S. Hebbal, G.B. Kulkarni, K. H. Prakash, S. S. Patil; May-2014, “Empirical Relation To
Estimate The Reduction Of Root Fillet Stress In Spur Gear Due To Elliptical Stress Relief
Features”
7. Pradeep Kumar Singh, Manwendra Gautam, Gangasagar and Shyam Bihari Lal; July 2014,
“Stress Analysis Spur Gear Design by Using Ansys Workbench”
8. Vivek Karaveer, Ashish Mogrekar and T. Preman Reynold Joseph; Dec 2013, “Modeling and
Finite Element Analysis of Spur Gear”

Web Sites
9. https://www.westyorkssteel.com/cast-iron-bar/s-g-iron/700-2

Books
10. Mechanical Engineering Design, Joseph E Shingley, Charles Mischke, Richard G Budynas,
Keith J Nisbett, the McGraw-Hill companies.
11. Design of Machine element, V. B. Bhandari
12. Hand Book of Gear Design, Gitin Maitry.

Thesis
13. Makwana rudreshkumar dineshbhai-june 2011 “Analysis of Plastic Spur and Plastic Helical
Gear under the effect of Tooth Deformation on Tooth Stresses and Contact Ratio using FEA”
14. Brenton L Ewing-November 2011, “Analysis of a hybrid (composite-metal) spur gear subjected
to stall torque using the finite element method” November-2013.

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