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Design and Analysis for Spur Gear by Using AGMA Standards and FEA: A
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 May – June 2020
ISSN: 0193-4120 Page No. 15086 - 15091

Design and Analysis for Spur Gear by Using AGMA

Standards and FEA: A Comparative Study
Maher Rehaif Khudhair
AL-Dewaniyah Technical Institute
AL-Furat Al- Awsat Technical University Iraq
maherrehaif@gmail.com, maher.khudhair@atu.edu.iq

Article Info Abstract:

Volume 83
Page Number: 15086 - 15091
Publication Issue:
May - June 2020
Article History
Article Received: 1May 2020
Revised: 11 May 2020
Accepted: 20 May 2020
Publication: 24May 2020
Power is transmitting by different methods; the spur gear is one of the most important
components used in power transmission of mechanical systems. This work presents the
effect of face width of gear teeth upon the strength of the spur gear and prepared the
analysis of stresses (bending and contact) for the mate teeth. The results gained from
Finite Element Analysis (FEA) are compared with AGMA (American Gear
Manufacturing Association) equation values, and the 3D model is designed by
SolidWorks 2017, saved in IGES format file, and then imported in the ANSYS 16.1
where it can be analyzed. Three models with different values were used in the face
width (30, 35, and 40 mm) that is given nearly comfortable of results with a little
percentage error different (4.74 % for bending and 4.84 % for contact). The results are
indicated, when the face width increases, stresses are decreases and vice versa. In
addition, from the observing of results, we can depend that the used Ansys software to
predict the stress values for the improves a design.
Keywords: Spur gear, Bending Stress, Contact Stress, AGMA, FEA

I. INTRODUCTION 40Ni2Cr1Mo28 at compared to steel C45. [2]

Investigated effect of the contact stress and
Gears, belts and chains drives are
deformation, and obtained from the numerical
generally defined mechanical drives. Also
analysis are compared with a theoretical error
called as a mechanism, which is intentional to
percentage is very less and it is the acceptable
transmitting of rotary motion and mechanical
ratio of contact stress. While the deformation is
power from one shaft to other, commonly
very little, that is neglected. [3] Focused on
involves a change in torque and speed in a wide
bending stress analysis based on face width as
diversity of applications. A spur gear is one of
the main parameter and obtained of results are
the utmost essential types of gears. It has
approximately similar from AGMA and FEM.
straight teeth and parallel axes of the shafts that
[4] Studied influence of pressure angle upon
carry of gears. Spur gear design and calculation
both stresses bending and contact were used
is required the tedious and wearily of
fourth types of angle (14.5, 20, 25, and 30) for
computations compared with modern
to analyses and then the results are validating
technology by used software. There are various
used for stresses founded in the gears teeth. [5]
stresses acting on the teeth during rotate gear,
Explained the range of involute effect on tooth
therefore it has required the best methods of
gear failure (stress and deflection) under static
analysis for the design to give accurate results.
and dynamic loading both analytical (theoretical
A previous study has examined as the
and numerical) and gets the results are good
following. [1] Used two-difference models by
agreement. [6] Revolved on the height of tooth
using 3D FEA and theoretical calc. and getting
gear to calculate bending stress and deflection
of weight reduction 22 % in steel
where divided height to three parts (9.1, 13.3,
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and 19.4) with different materials and explained
the difference of results in theoretical and
software for both parameters. [7] Depended on
the face width to evaluate of bending stress
during theoretical, numerical, Matlab, and their
outcomes are acceptable. [8] Investigated
bending stress as the main cause of failure of
gear tooth during power transmission based on
the module of gear as the important parameter
(3.5, 4, 5, and 6), the results compared the
Ansys with theoretical are nearly equal, and the
percentage error from (1.06 to 3.74 %). [9] Used
cast iron and carbon fiber as optimized material
to analyze of (deformation, equivalent strain,
and equivalent stress) by ANSYS, and the study
reported that carbon fiber it is the high modulus
of the material is appropriate for the
manufacturing of spur gear.
Aim of study the focused on the effect of
face width as a major parameter acting upon
tooth failure under dynamic loading through to
the gear rotates. A suitable material used for the
pinion and gear are the same (Alloy steel AISI
1040), [10, 11], properties shown in the table
(1), and parametric geometry of gear and pinion
are tabulated in the table (2). The mathematical
model and symbols were used according to the
AGMA standards (American Gear
Manufacturers Association) as a design
parameter factors [12].
Pitch diameter (dp)
2 54 150
in (mm)
Face width (F) in 30, 35,
3 30, 35, 40
(mm) 40
4 Module (mt) 3 3
Pressure angle (φ) in
5 20 20
degree
II. STRESS CALCULATION BY
AGMA
W. Lewis (1892) is the first introduced an
equation for calculating the bending stress in
gear teeth as a cantilever beam. Today, known
called is Lewis equation and assumed that is
load will be transmitted from one gear to other;
it is all transmitting by one tooth. In addition, it
still renders the basis for the estimate of gear
tooth bending stress analysis. Some of
simplifying assumption in the approach of
Lewis as (a load is acts to the tip of one tooth,
the forces of radial component and sliding
friction are negligible, uniformly distributed
load UDL across the face width, and negligent
of stress concentration in the tooth). The
equation (1) explained of bending stress as a
general of Lewis formula, and fig. (1) showed
cross-sectional of a cantilever beam. Where the
face width (b), thickness (t), and length (l) of the
gear tooth.

Table (1) Properties of AISI 1040 [10, 11]

Tensi
Appr Har Yield
Modulu le
ox. dne Stren Dens Poisso
s of Stren
% ss gth ity n’s
Elasticit gth
Carb BH (MPa k/m3 ratio
y (GPa) (MPa
on N )
) Fig. 1. Gear tooth as a cantilever beam [13]
0.4 200 206 415 683 7845 0.29
FtP
 (1)
FY
Table (2) Geometry parameters
No. Parameters Pinion Gear Where:
1 No. of teeth (Z) 18 54

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2xP values of face width (30, 35, and 40 mm) both

Y is Lewis form factor and P = π/p is
3 the pinion and gear and saved as IGES as format
diametral pitch and (p) is circular pitch of gear file. Import IGES mode in Ansys 16.1 –
and Ft is tangential force acting upon tooth. The Workbench simulation and apply materials for
major equations of stresses (bending and spur gear in static structural as shown in the fig.
contact) that explained in equations (2) and (3) (3). Mesh generation of spur gear pair as shown
in Mega Pascal [13]. in fig. (4), and mesh generated was done by a
fine situation to obtain the good quality of the
1 KH KB
 b  Ft K o H v K s (2) mesh.
bmt YJ

Km C f
 c  C p Ft K o H v K s (3)
dp b I

Where (Cp) is an elastic coefficient in ( MPa )

1
 2 Fig. 2. 3D modeling of assembly of spur gears
 
 1 
Cp   (4)
 
  1   p  1  G  
2 2

  Ep E G  


For steel alloy AISI 1040, Cp = 190 MPa 0.5 and

the calculations have been completed according
to recommended by AGMA standard [14] and
[15].
Where the operation conditions: Fig. 3. 3D modeling solid imported
Power transmitted (P) = 20 kW, and
Speed (N) = 1400 r.p.m.
III. FINITE ELEMENT ANALYSIS
(FEA)
Finite element method is a numerical technique
of analysis used to the solution of engineering
problems as a predictive value for pre-design;
its purpose is to prevent failure by choosing the
right material for the appropriate application.
Because of its flexibility and variety as Fig. 4. Mesh generation of helical gear
analytical tools, that is received a lot of attention
IV. RESULTS AND DISCUSSIONS
in mechanical industries today. Therefore, it is
necessary to achieve approximately solution to Face width of the gear tooth is very important
problems to some extent. The fig. (2) describes geometry parameter in estimating the situation
of 3D assembly in Solidworks 2017 at three of stresses (bending and contact) through the

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 May – June 2020
ISSN: 0193-4120 Page No. 15086 - 15091

design of gear. To determine the variation of

stresses with the third difference of face width
different cases of spur and retain other
parameters are constant. Therefore, the results
data for FEA and theoretical according to
AGMA standards as tabulated in tables (3 and
4) that is explained the comparison of stresses,
while figures (5 to 10) shows a numerical
analysis of bending and contact stresses by
FEA. Fig. 5. Bending stress of spur gear b = 30 mm

Table (3) Comparison of Bending stress results

Bending
Bending
Face Stress by
AGMA Stress by Difference
Case width
Ansys in ( % )
(mm) Standard
(MPa)
( MPa)
Case 30
291.42 300.75 3.1
1
Case 35 Fig. 6. Bending stress of spur gear b = 35 mm
264.792 277.82 4.6
2
Case 40
244.227 256.38 4.74
3

Table (4) Comparison of Contact stress results

Contact
Contact
Face Stress by
Stress by Difference
Case width AGMA
Ansys in ( % )
(mm) Standard
(MPa)
( MPa)
Case 30 Fig. 7. Bending stress of spur gear b = 40 mm
1500.164 1561.6 3.93
1
Case 35
1429.986 1485.4 3.73
2
Case 40
1373.334 1443.3 4.84
3

Fig. 5. Contact stress of spur gear b = 30 mm

Published by: The Mattingley Publishing Co., Inc. 15089


Fig. 5. Contact stress of spur gear b = 35 mm
Fig. 5. Contact stress of spur gear b = 40 mm
V. CONCLUSIONS
This study focused on the validation of the
effectiveness of face width on the strength of
gear tooth is studied by a variety of the face
width, which is (30, 35, and 40 mm) theoretical
calculation by AGMA both stresses bending and
contact to compare to the FEA. That is given
nearly comfortable of results with a little
percentage error different (4.74 % for bending
and 4.84 % for contact). The results are
indicated, when the face width increases,
stresses are decreases and vice versa. In
addition, from the observing of results, we can
depend that the used Ansys software to predict
the stress values for the improves a design.
Also, recommended in a future study can be
investigated gear mesh under dynamic loading
with or without cracked and wear surface.
VI. REFERENCES
[1] S. Prabhakaran, Dr. S. Ramachandran,
Comparison of bending stress of a
spur gear for different materials and
Published by: The Mattingley Publishing Co., Inc.
May – June 2020
ISSN: 0193-4120 Page No. 15086 - 15091
modules using AGMA standards in
FEA, Advanced materials research,
Vol. 739, 2013, pp. 382–387.
[2] Vivek Karaveer, Ashish Mogrekar, T.
Preman Renold Joseph, Modeling
and finite element analysis of spur
gear, International journal of current
engineering and technology, Vol. 3,
No. 5, 2013, pp. 2104–2107.
[3] Abdurrahman Ahmed Umar,
Abdulrahman Shuaibu Ahmad,
Auwalu Gidado Youssf, Zulfiqar
Ibrahim Bibi Farouk, Effect of face
width on bending stress of spur gear
using AGMA and FEA, Advanced
materials research, Vols. 945–949,
2014, pp. 840–844.
[4] Krishanu Gupta, Sushovan Chatterjee,
Effect of pressure angle of spur gears
on bending and contact stresses: A
comparative study using finite
element software, International
journal of advanced research in
science and engineering, Vol. No. 4,
Special Issue (01), 2015, pp. 517–
526.
[5] Pinaknath Dewanji, Design and analysis
of spur gear, International journal of
mechanical engineering and
technology, Vol. 7, Issue 5, 2016,
pp. 209–220.
[6] Joginder Singh, Dr. M R Tyagi, Analysis
of stresses and deflections in spur
gear, International journal of
mechanical engineering and
technology, Vol. 8, Issue 4, 2017,
pp. 461–473.
[7] Amit Patil, Bending stress analysis of
spur gear, International journal for
research in applied science &
engineering technology, Vol. 5, Issue
VI, 2017, pp. 422–426.
15090

[8] Puspraj Singh, Gaurav Verma, Dr. L.P.
Singh, Design and analysis of stress
induced in spur gear tool profile
using CATIA and Ansys,
International journal of engineering
and techniques, Vol. 3, Issue 5,
2017, pp. 118–124.
[9] B. Sivakumar, Joe Michael, Design and
stress analysis of spur gear,
International research journal of
engineering and technology, Vol. 5,
Issue 5, 2018, pp. 1153–1156.
[10] Ismail Ali Bin Abdul Aziz and et al,
Finite element analysis of impact
energy on spur gear, MATEC Web
of Conferences 225, 06011 (2018).
[11] Dudley’s Gear Handbook, The
design, manufacture, and application
of gears, McGraw−Hill Education
(India) private limited, New Delhi,
Second edition, 2013, p. 320.
[12] Shigley’s, Mechanical Engineering
Design, McGraw−Hill Primis,
Eighth Edition, 2008, pp. 715–724.
[13] [13] Ansel C. Ugural, Mechanical
design of machine components, CRC
Press - Taylor & Francis Group,
Second edition, 2015, p. 527.
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ISSN: 0193-4120 Page No. 15086 - 15091
[14] [14] American gear manufacturing
association, Geometry factors for
determining the resistance and
bending strength of spur, helical and
herringbone gear teeth, AGMA 908–
B89, 1999, p. 38.
[15] American national standards,
Fundamental rating factors and
calculation methods for involute spur
and helical gear teeth, ANSI/AGMA
2001–D04, 2005, pp. 9–22.
NOMENCLATURE
Ko – Overload factor
Kv – Dynamic factor
Ks – Size factor
KH – Load distribution factor
KB – Rim–thickness factor
YJ – Geometry factor
Cp – Elastic coefficient ( MPa )
Cf – Surface condition factor
I – Geometry factor for pitting resistance
Ft – Tangential force (N)
σb – Bending stress (MPa)
σc – Contact stress (MPa)
15091