International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 4, Issue-7, Jul.

-2016

A REVIEW ON DESIGN, ANALYSIS AND SHAPE OPTIMIZATION OF

SPUR GEARS OF THE GEAR-BOX REDUCTION OF THE WORKING
WHEEL OF THE EXCAVATOR SCHRS 1300 24/5.0 USING CAD/CAE
SOFTWARE
1
FATMIR AZEMI, 2BEKIM MALOKU, 3MUSAJ TERBUNJA
1
PhD student at Josip Juraj Strossmayer University Of Osijek, Mechanical Engineering Faculty- Slavonski Brod, Republic of
Croatia, 2Teacher at Secondary Technical School “L.utfi Musiqi” Vushtrri-Republic of Kosovo
3
Director in Department of Education in Municipality, Vushtrri-Republic of Kosovo
E-mail: 1fatazemi@hotmail.com, 2bekim.m70@hotmail.com, 3musajterbunja@postribe.com

Abstract- Gears are one of the most important components in mechanical power transmission systems. The bending and
surface strength of the gear tooth are considered to be one of the main contributors for the failure of the gear in gear set. The
three dimensional solid model can be generated in CAD software, in this case we have created model in Autodesk Inventor
2015. This model of the spur gears are imported in ANSYS software and then contact stress and bending stress can be
calculated in ANSYS. The paper presents the results of calculation of pair spur-gears that it used in the gear-box reduction of
the working wheel of the Excavator located in open-cast coal mines in “Bardhi i Madh - Fushë Kosovë” , and after that will
be optimized the shape of the spur gear with usage of ANSYS software. To be more specific, how much material can be
removed from the gear body without compromising the gear meshing properties? Consequently, the aim of this research is to
reduce weigh of the gears.

Keywords- CAD/CAE software, FEM, Stress-Strain Analysis, Spur-Gear, Shape Optimization CAD-Computer Aided
Design, CAE-Computer Aided Engineering, FEM-Finite Element Method

I. INTRODUCTION our overall objective and purpose of this study is to

Reduction of material has been one the critical
aspects of any design along with reduction in
deformation and stress factors, which increases the
life of the product. Structural optimization tools like
topology and shape optimization along with
manufacturing simulation are becoming attractive
tools in product design process. These tools also help
to reduce product development time. This paper
presents design, analysis and shape optimization in
order to reduce material of spur gears and focuses on
static analysis. Finite element analysis has been used
to implement optimization and maintaining stress and
deformation levels.
II. STATEMENT OF THE PROBLEM,
OBJECTIVES AND PURPOSE OF THE STUDY
In the last published paper with titled “Stress-Strain
Analysis of the Spur Gear of the Gear-box Reduction
of the Working Wheel of the Excavator Schrs 1300
24/5.0 using CAD/CAE Software” we have
presented the results of analysis of stress-strain of
spur gear of the gear-box reduction of the Excavator.
In that case we have found out that during Excavator
arm movement from right side to left the bucket
wheel works with maximum capacity and in that case
have been caused damage in spur gear 9 and spur
gear 10 of gear-box reduction of the Excavator. After
the Stress-Strain Analysis of the Spur Gear, we found
out that the Spur Gear didn’t accomplish working
conditions with that geometry and material used, so,
determine:
- which factors aren’t accomplished,
- finding a solution that spur gear fulfill conditions,
and
- shape optimization of the spur gear
III. METHODOLOGY AND MATERIALS
CAD is used mainly for the creation of detailed 3D
solid or surface models, or 2D vector-based drawings
of physical components. However, CAD is also used
throughout the engineering process from conceptual
design and layout of products, through strength and
dynamic analysis of assemblies. In this case we have
used CATIA V5, Autodesk Inventor Professional and
ANSYS software for design, analysis and shape
optimization of parts and their assembly.
Based on the result from the last paper, in this paper
first thing is to determine that, which conditions the
spur gears didn’t fulfill. Autodesk Inventor
professional 2015, Spur Gears Component Generator
is used to generate a pair of gears with same
geometry and material as shown below on tables.
Method of Strength Calculation based on ISO
6336:1996.
Parameters, geometrical data, materials and loads are
given through tables as below:
Table 1. Common parameters:

A Review On Design, Analysis And Shape Optimization Of Spur Gears Of The Gear-Box Reduction Of The Working Wheel Of The
Excavator SCHRS 1300 24/5.0 Using CAD/CAE Software

19
International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 4, Issue-7, Jul.-2016

Fig,1. Section view of main geometrical data

Table 3. Loads

Table 2. Main Geometrical Data of Gears

Table 4. Materials

A Review On Design, Analysis And Shape Optimization Of Spur Gears Of The Gear-Box Reduction Of The Working Wheel Of The
Excavator SCHRS 1300 24/5.0 Using CAD/CAE Software

20
International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 4, Issue-7, Jul.-2016

As we can see from table 6 these conditions the pair

gears didn’t fulfill:
- Factor of safety from Pitting is SH9=1.077
for Gear 9,
- Factor of Safety from Tooth Breakage
SF9=0.905 and SF10=0.905,
- Static Safety in Contact SHst9=0.676 and
SHst10=0.676.
Based on the calculation from tables, numbers of
teeth are commensurable but factors of safety
presented that the pair gears must be check
calculation, we can check material design or
geometry design, but due to geometry of spur gears is
depended from another pieces of gear-box reduction
of the Excavator, we must choose to check material
of gears. On tables 7 and 8 are shown results after
checked material design of pair spur gears.

Table 5. Factors
Fig.2. Teeth mesh after the pair of spur gears is generated

Solid generation the pair spur- gears is shown in

fig.3.

Fig.3. The main generation of spur gears in Autodesk Inventor

Professional

This geometry of assembly could be transferred or

Table 6. Results redesign in any CAD software such as: CATIA,
AutoCAD, Soldiworks, est. with the same
dimensions. The analysis of design reviewed and
shape optimization of spur gear are done with Finite
Element Method – ANSYS software.

IV. ANALYSIS AND SHAPE OPTIMIZATION

OF SPUR GEAR WITH FINITE ELEMENT
METHOD-ANSYS WORKBENCH

Parametric design of spur gear 9 is built in CATIA

V6 (fig.4) with the same dimensions taken from
A Review On Design, Analysis And Shape Optimization Of Spur Gears Of The Gear-Box Reduction Of The Working Wheel Of The
Excavator SCHRS 1300 24/5.0 Using CAD/CAE Software

21
International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 4, Issue-7, Jul.-2016

model that is generated in Inventor Professional, and Material Design”. Results are given on tables as
has been exported in ANSYS software for the below.
analysis and shape optimization (fig.5,6).
Table 7. Characteristics of Material after application method
material design

Fig.4. Parametric design of spur gear 9 in CATIA

Fig.5. Meshed 3-D Model of Spur gear-ANSYS software

Fig.6. Red color shows zone that needed to be removed for

shape optimization

V. RESULTS AND DISCUSSION

The gears (pinion and gear) are calculated in

Inventor, the tools Spur Gears Component
Generator has created components (fig.3) after
application method of “Type of Strength Calculation-
A Review On Design, Analysis And Shape Optimization Of Spur Gears Of The Gear-Box Reduction Of The Working Wheel Of The
Excavator SCHRS 1300 24/5.0 Using CAD/CAE Software

22
International Journal of Mechanical And Production Engineering, ISSN: 2320-2092,
Table 8. Results of spur gears in Inventor
Table 9. Mass reduction after the process of optimization –
ANSYS software (FEM method)
Are designed three of different model geometries and
evaluated in relation to static transmission using
solver. The tooth geometry and load remained the
same. A parametric model is shown in fig.7.
Fig. 7. Different model geometries after shape optimization-
CATIA V6
CONCLUSION
They are a number of the components of the design
process including calculations, material strengths,
duty, and manufacture quality that are indicating in
product development.
In this paper geometry integration of the spur gear is
used in order for relational design to be successfully
implemented, all parts and products need to be
parameterized. The spur gears geometry can be
generated using mathematical calculations done in
Autodesk Inventor professional and CATIA supports
parametric design, through which gear geometry
formula and relations are created. The model of spur
gear 9 has been exported in ANSYS software for
shape optimization. The design optimization helps in

A Review On Design, Analysis And Shape Optimization Of Spur Gears Of The Gear-Box Reduction Of The Working Wheel Of The
Excavator SCHRS 1300 24/5.0 Using CAD/CAE Software
23
Volume- 4, Issue-7, Jul.-2016
reducing 20.5% of the structure weight (the initial
and final mass of the spur gear are 669.58 kg and
538.48 kg, respectively), which in turn reduces the
cost of the spur gear with safe design.
Based on the results from shape optimization (fig. 6),
the model of spur gear is redesign in CATIA V6
(fig.7).
REFERENCES
[1]. Simpson, T. W., Toropov, V., Balabanov, V., and Viana, F.
A. C. "Design and Analysis of Computer Experiments in
Multidisciplinary Design Optimization," 12th AIAA/ISSMO
Multidisciplinary Analysis and Optimization Conference
AIAA 2008-5802, Victoria, British Columbia, Canada,
September 2008.
[2]. Mr.sc. Fatmir Azemi, Dr.sc. Gani Pllana, Msc. Musaj
Turbunja, Msc. Bekim Maloku: Stress-Strain Analysis of the
Spur Gear-Box Reduction of the Working Wheel of the
Excavator SchRs 1300 24/5.0 Using CAD/CAE Software;
SER-12th International Conference on Science, Technology,
Engineering and Management (ICSTEM) held in Istanbul
Turkey on 4th March 2016, paper ID: IS-STEMTURK -
4036-02.
[3]. Orr, S. A., and Narducci, R. P. "Framework for
Multidisciplinary Analysis, Design, and Optimization with
High-Fidelity Analysis Tools." NASA/CR-2009-215563,
February 2009.
[4]. Gunduz, M. E. "Software Integration for Automated Stability
Anaylsis and Design Optimization of a Bearingless Rotor
Blade," Phd Thesis, School of Aerospace Engineering.
Georgia Institute of Technology, Atlanta, GA, May 2010.
[5]. Ochęduszko, K.: "Koła zębate", Warszawa, 1976.
[6]. Tochtermann/Bodenstein: "Konstruktionselemente des
Maschinenbaues",Teil 2, Springer-Verlag Berlin Heidelberg
New York, 1979.
[7]. Niemann, G.; Winter, H.: "Maschinenelemente" Band II,
pringer-Verlag Berlin Heidelberg New York Tokyo, 1985.
[8]. F. P. Beer, E. R. Johnston, J. T. DeWolf,x and D. F. Mazurek,
Mechanics of Materials, 6th ed.(McGraw-Hill, New York,
2011).
[9]. J. E. Shigley, C. R. Mischke, and R. G. Budynas, Mechanical
Engineering Design, 7th ed. (McGraw-Hill, New York,
2003).
[10]. Y. Nakasone, S. Yoshimoto, T. A. Stolarski; Engineering
Analysis With ANSYS Software-Printed and bound by MPG
Books Ltd., Bodmin, Cornwall.
[11]. The Finite Element Method for Mechanics of Solids with
ANSYS Applications, Ellis H. Dill; CRC Press Taylor &
Francis Group 6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742, 2011.
[12]. OSITA D. I. NWOKAH YILDIRIM HURMUZLU: THE
MECHANICAL SYSTEMS DESIGN, Southern Methodist
University, Dallas, Texas, 2002.
[13]. Cornelius, L.: “COMPUTER INTEGRATED
MANUFACTURING”, Boca Raton, London New York
Washington, D.C., 2001.
[14]. Radhakrishnan, P.; Subramanyan, S.; Raju, V.:
“CAD/CAM/CIM”, New Delhi, 2008.
[15]. F. Azemi, “The analysis and optimization of the factors that
indicate in the construction of machines with the aid of
computer”, Prishtine 2004 .
[16]. Richard G. Budynas and J. Keith Nisbett:” Mechanical
Engineering Design”, The McGraw-Hill Companies, 2008.
[17]. Sham Tickoo, “CATIA V5-6R2014 for Designers”,
CAD/CIM Technologies Schererville, Indiana 46375, USA.
[18]. Zeid, I. CAD/CAM Theory and Practice: McGraw-Hill, Inc.,
1991