FRICTIONAL ANALYSIS OF SPUR GEAR WITH

SPECIAL METALLIC COATING

A PROJECT REPORT
Submitted by
BALAJI J
HEMAMANIMARAN D
SATHISH RS
In partial fulfillment for the award of the

degree Of

BACHELOR OF ENGINEERING

In

MECHANICAL ENGINEERING

ADHIPARASAKTHI ENGINEERING COLLEGE, MELMARUVATHUR

ANNA UNIVERSITY
CHENNAI 600 025

MARCH 2021
 ANNA UNIVERSITY
CHENNAI 600 025

BONAFIED CERTIFICATE

Certified that this project report “FRICTIONAL ANALYSIS OF SPUR GEAR WITH
SPECIAL METALLIC COATING” is the bonafied work of

BALAJI J 420417114012
HEMAMANIMARAN D 420417114030
SATHISH RS 420417114067

Who carried out the project work under my supervision

SIGNATURE SIGNATURE
(Dr.S.GOPALAKANNAN.M.E.,Ph.D.,) (Mr.R.SATHISHBABU, M.E.)
HEAD OF THE DEPARTMENT SUPERVISOR
Professor Assistant Professor
Dept. of Mechanical Engineering Dept. of Mechanical Engineering
Adhiparasakthi Engineering college. Adhiparasakthi Engineering college.

Submitted for the university examination held on ………………

INTERNAL EXAMINER EXTERNAL EXAMINER

 ACKNOWLEDGEMENT

We inhale pleasure in thanking our President HIS HOLINESS ARUL THIRU

AMMA and our vice President SAKTHI THIRUMATHI AMMA for having given us
this wonderful opportunity to implement our idea.

We also express our sincere thanks to our Correspondent SAKTHI THIRU

Dr.G.B.SENTHIL KUMAR, who has been constantly supporting all our
endeavours.

We are express our thanks to our respected Principal Dr.J.Raja , and Head of
the department Dr.S.Gopalakannan, and our project Co-ordinator
Mr.K.DHANDAPANI , who has been constantly supporting all our endeavours.

We also thank our internal Guide Mr.R.SATHISHBABU, Mechanical

Department whose valuable suggestion has helped us to complete the project
successfully.

We thank all our staff members both teaching and non-teaching who have
contributed their ideas for betterment of the project. Last but not least we extend
our sincere thanks to all the staff members who have contributed their ideas for
the betterment of the project
 ABSTRACT

Spur gear is used to transfer rotary motion between parallel shafts. The
simplicity in its design is one of the advantages of the spur gear. However higher
frictional force that is accumulated on the gear teeth will influence the spur gear
performance the contact stress of spur gear has been evaluated with and without
friction by employing the Hertz theory, AGMA standard and finite element method
(FEM). The frictionless contact stress result has been validated with both the
theoretical methods with minimum deviation. Frictional coefficient range of 0.0 to
0.3 was selected and the corresponding contact stress is directly proportional to the
friction coefficient. The work also involves the variation of face width of the gear
set under the influence of friction. The contact stress of spur gear was found to be
inversely proportional to the face width. Here the carbon fiber and epoxy resin
coating is applied on the spur gear.

i
CHAPTER TITLE PAGE
NO. NO.
ABSTRACT i

1.Introduction 1
2.Literature Review
2.1.Structural Analysis of Spur Gear 5
2.2.Contact And Bending Stress Anasysis Of Spur Gear 6
2.3.Stress Analysis On Spur Gears Using Ansys 6
3.Spur Gear 8
3.1.Dimension Specifications 11
3.2.Mounting Specifications 13
3.3.Spur Gear Materials 14
3.4.Applications 15
4.Methodology 17
5.Solid Works 2018 18
5.1.Introduction To Finite Element Method 19
5.2.General Procedure Of Finite Element Method 20
5.3.Convergence Requirment 22
5.4.Advantages Of FEM 23
5.5.Limitations In FEM 23
5.6.Applications Of FEM 24
6.FEA Software – ANSYS
6.1.Introduction to ANSYS Preogram 26
6.2.Evolution Of ANSYS Program 26
6.3.Overview Of The Program 26

ii
 6.4. Reducing the design and manufacturing costs using ANSYS 29
6.5. Program availability 29

6.6.Analysis types available 30

6.7. Procedure for ANSYS analysis 30

6.8. Geometrical definitions 32

6.9. Model generations 32

6.10. Mesh generation 33

6.11. Finite element generation 33

6.12. Model display 34

6.13. Material definitions 34

6.14. Solution 35

7.Ansys Procedure 36

8.Conclusion 43

9.Reference 44

iii
 CHAPTER 1

INTRODUCTION

Gear is the most common means of power transmission system in modern

mechanical engineering world. It is a positive drive maintaining constant velocity
ratio and possesses high efficiency in transmission. Among the various types gears
spur gear with involute profile is the simplest considering the design and
manufacturing cost. In this paper static analysis of the spur gear in the existing
automobile gear box has been discussed with various torque specifications. The
modern power transmission system requires highly efficient gear, for that the
evaluation of stress and deflection of the tooth is vital.

Research work on this field revealed that for determining the practical
strength the compressive and shear stresses on the tooth are neglected as their
effects are marginal as compared to the bending stress. This paper also establishes
the above concept for stress on the gear tooth under matting and rotating condition.
Apart from that, the study of stress on the tooth is important to predict and estimate
the critical value beyond which the gear would fail. A pair of teeth in action
generally fail by two types of stresses; namely bending fatigue due to bending
stress at the root of the tooth and the another one is the contact fatigue which is a
surface failure.

Highest stress occur at two locations i.e. the point at which the force acts and
the root of the tooth. A lot of research works have been carried out on this gearing
technology considering its material, geometrical parameters, manufacturing
processes and some are going on for the betterment. S. Kumar, K. Mishra, J.
Madan presented the FEA method to analysis the stress on tooth and established
that the bending stress and contact stress are major sources of gear failure. Kailash
C.Bhosale in his paper a comparison study has been presented between the lewis
equation and the FEA method for calculating the bending strength in case of

1
helical gear with straight tooth. Shubham et al, have worked out the static and
dynamic analysis of a single tooth of spur gear using ANSYS 16.0 considering the
velocity factor approximation. Extensive research has been carried out for
reduction of root stress and for that attention has taken to the tooth fillet, the
location where the fracture initiates. This work has been extended to evaluate the
tooth strength of involute profile considering the asymmetric and symmetric gear
with static and dynamic loading.

A reduction of bending stress has also been established by introducing the

circular root fillet in comparison to the standard root fillet. A number of research
studies have been carried out in this context to replace the material of the gear to
enhance the loading capacity by reducing the stress and total deformation induced
on the tooth along with the reduction the overall weight of an automobile Anuj
Nath et al., in their work, have shown the design and analysis of a composite spur
gear made of 50% carbon fibers in epoxy resin matrix and compared to steel gear,
0.5324% lesser stress and 55.619% reduction in total deformation have been found
for the composite gear.

Study has been carried out on the choice of gear tooth profile and is found
that only involute and cycloidal curves satisfy the law of gearing. Involute gears
have certain advantages over the cycloidal gears like varying center distance with
constant velocity ratio during matting, constant pressure angle with less wear and
finally ease of manufacturing. The only problem with the involute profile is the
interference. Although the cycloidal gear is not totally obsolete. It is used in spring
driven watches, in some instruments. The most common gear-cutting processes
include hobbing, broaching, milling, and grinding. Such cutting operations may
occur either after or instead of forming processes such as forging, extruding,
investment casting, or sand casting. The present course of study concentrates on
the manufacturing of gear based on composite materials at the critically stressed
section with the help of software based analysis. Generative manufacturing or any
2
other forms of layer-by-layer manufacturing methods could be employed for the
generation of gear in this regard.

Gears are toothed members which transmit power / motion between two
shafts by meshing without any slip and the power is usually transferred in such a
way velocity ratio remains constant. In any pair of gears, the smaller one is called
pinion and larger one is called gear immaterial of which is driving the other. When
pinion is the driver, it results in step down drive in which the output speed
decreases and the torque increases. On the other hand, when the gear is the driver,
it results in step up drive in which the output speed increases and the torque
decreases. Gears are classified as spur, helical, double helical, bevel, worm and
spiral gears. The contact stress and fatigue analysis of both spur and helical gear
drive are examined in this research and it will be useful for further investigators to
improve gear behaviors on various aspects.

The need for visualizing, simulation, analysis and documenting mechanical

parts prior to production has existed ever since human beings began creating
machines, mechanisms, and products. Over the last decades, methods for achieving
this function have been developed dramatically. Today, powerful computer
hardware and software have supplanted the manual drafting and have advanced to
the point of playing a pivotal role in not only improving design visualization but
also in driving the entire manufacturing process. Computer Aided Design (CAD) is
assistance of computer in engineering processes such as creation, optimization,
analysis and difications.

It is an integration of Mechanical and Computer technology to aid in the

design process like Modeling, Assembly, Drafting, Die Design, Tool Design, Sheet
metal, analysis of products. In this paper we have used SOLID WORKS 2018
software as CAD software for modeling of spur gears as well as their assembly.
Computer Aided Engineering (CAE) is the use of Computer to support engineers
in tasks such as analysis, simulation, design, manufacture, planning, diagnosis, and
3
so on. ANSYS Mechanical and ANSYS Multiphysics software are non-exportable
analysis tools incorporating pre-processing (geometry creation, meshing), solver
and post-processing modules in a graphical user interface. These are general-
purpose finite element modeling packages for numerically solving mechanical
problems, including static/dynamic structural analysis (both linear and non-linear),
heat transfer and fluid problems, as well as acoustic and electro-magnetic
problems. In our case ANSYS Workbench 16.0 is used for Stress-Strain Analysis
of the spur gear of the gearbox reduction of the working wheel of the Excavator.

Gears usually used in the transmission system are also called speed reducer,
gear head, gear reducer etc., which consists of a set of gears, shafts and bearings
that are factory mounted in an enclosed lubricated housing. Speed reducers are
available in a broad range of sizes, capacities and speed ratios. In this paper,
analysis of the characteristics of spur gears in a gearbox will be studied using
linear Finite Element Method. Gear analysis was performed using analytical
methods, which required a number of assumptions and simplifications. In this
paper, bending stress analysis will be performed, while trying to design spur gears
to resist bending failure of the teeth, as it affects transmission error. As computers
have become more and more powerful, people have tended to use numerical
approaches to develop theoretical models to predict the effect of whatever is
studied. This has improved gear analysis and computer simulations. Numerical
methods can potentially provide more accurate solutions since they normally
require much less restrictive assumptions. The finite element method is very often
used to analyze the stress state of an elastic body with complicated geometry, such
as a gear. There are two theoretical formulas, which deal with these two fatigue
failure mechanisms. One is the Hertz equation, which can be used to calculate the
contact stresses and other is the Lewis formula.

4
 CHAPTER 2

LITERATURE REVIEW

1. STRUCTURAL ANALYSIS OF SPUR GEAR - Sushovan Ghosh ,

Rohit Ghosh , Bhuwaneshwar Patel , Tanuj Srivastava , Dr.
RabindraNath Barman Assistant Professor, , NIT Durgapur,
Durgapur, India

Gear is basically a toothed wheel. But, it is one of the most important machine
elements in mechanical power transmission system. It has a wide range of
applications starting from wrist watch to heavy industries due to its high degree of
reliability and compactness. Reckoning the bending stress and total deformation of
gear tooth is considered to be the paramount objective for modern gear design
industry. The present work is an attempt to estimate the root-bending stress and
total deformation of a spur gear tooth. Dimensions of the gear tooth are taken from
practical understanding and is analysed for different torque specifications of the
three existing vehiclemodels of Maruti Suzuki using ANSYS (Workbench R14.5)
software considering structural steel as tooth material. The present study also
concentrates on the manufacturing of gear based on composite materials at the
critically stressed section with the help of software based analysis. We suggest
that, generative manufacturing or any other forms of layer-by-layer manufacturing
methods could be employed for the generation of precision gears in this regard.
Validation of the cantilever beam concept and Castigliano’s theorem associated
with the analytical calculation of gear design, has also been contemplated in the
present work.

5
 2. CONTACT AND BENDING STRESS ANALYSIS OF SPUR GEAR
In this paper, the main purpose is first, to determine contact stress
on involute spur gear teeth by using analytical and numerical approaches and
compare the result of these approaches. Using specifications of a gear, a model is
generated and the process of obtaining the model is automated with a computer
program developed in this study. Using data from the model, Hertz contact stresses
are determined by using analytical formulation. The same model is used for finite
element analysis for obtaining contact stresses by using ANSYS software. For a
mesh cycle, variations of contact stresses obtained from the two approaches, are
determined for different gear ratios. Except at the contact points of the tip point of
pinion with the root of the mating gear, numerical results were in good agreement
with the analytical results. It was also noticed that, level of contact stress decreases
when gear ratio (or contact ratio) increases. Additionally, in order to see how
bending stresses at the root of pinion and gear is varied due to change of contact
point in a mesh cycle, bending stress variation is evaluated and included in the
content of this study. For different gear ratios, it was noticed that variation of
bending stress in a mesh cycle has the same nature with the contact stress variation
but magnitudes are smaller with respect to contact stresses

3. STRESS ANALYSIS ON SPUR GEARS USING ANSYS-May Phyoe

Thu Dept. of Mechanical Engg. Technological University Hmawbi,
Myanmar Nwe Lin Min Dept. of Mechanical Engg. Technological
University Hmawbi, Myanma

Gear is one of the most important machine elements in mechanical power

transmission system. It is a rotating machine part having cut tooth which meshes
with another tooth part in order to transmit torque. The application of gears has a
wide range starting from tiny wrist watch to huge heavy machinery such as
automobile, aerospace industry and marine engines due to its high degree of
6
reliability and compactness. Spur gears have straight tooth and are parallel to the
axis of the wheel. The bending stress and total deformation of gear tooth is
considered to be the paramount objective of for modern gear design. A pair of spur
gear tooth in action is generally subjected to two types of cyclic stress, contact
stress and bending stress including fatigue. In this paper, the contact stress analysis
of stainless steel spur gear by theoretical method using Hertz equation and Finite
element analysis using ANSYS 16.0 workbench. The present work is an attempt to
find root bending stress distribution, maximum allowable contact stress and total
deformation of a stainless steel spur gear tooth.

7
 CHAPTER 3

SPUR GEARS

Spur gears are simple, easily manufactured gears and are usually the first
choice when exploring gear options. Transmitting power between parallel axes, the
teeth project radially on the disc. Spur gears are regularly used for speed reduction
or increase, torque multiplication, resolution and accuracy enhancement for
positioning systems. The teeth run parallel to the gear axis and can only transfer
motion between parallel-axis gear sets. Spur gears mate only one tooth at a time,
resulting in high stress on the mating teeth and noisy operation.
Spur gears are a type of cylindrical gear, with shafts that are parallel and
coplanar, and teeth that are straight and oriented parallel to the shafts. They’re
arguably the simplest and most common type of gear – easy to manufacture and
suitable for a wide range of applications. The teeth of a spur gear have an involute
profile and mesh one tooth at a time. The involute form means that spur gears only
produce radial forces (no axial forces), but the method of tooth meshing causes
high stress on the gear teeth and high noise production. Because of this, spur gears
are typically used for lower speed applications, although they can be used at almost
any speed.

An involute gear tooth has a profile that is the involute of a circle which
means that as two gears mesh, they contact at a single point where the involutes
meet. This point moves along the tooth surfaces as the gears rotate, and the line of
force (known as the line of action) is tangent to the two base circles. Thus, the
gears adhere to the fundamental law of gearing, which states that the ratio of the
gears’ angular velocities must remain constant throughout the mesh.

8
Spur gears can be made from metals such as steel or brass, or from plastics such as
nylon or polycarbonate. Gears made of plastic produce less noise, but at the
expense of strength and loading capability. Unlike other gear types, spur gears
don’t experience high losses due to slippage, so they generally have high
transmission efficiency. Multiple spur gears can be used in series (referred to as a
gear train) to achieve large reduction ratios.

There are two primary types of spur gears: external and internal. External
gears have teeth that are cut on the outside surface of the cylinder. Two external
gears mesh together and rotate in opposite directions. Internal gears, in contrast,
have teeth that are cut on the inside surface of the cylinder. An external gear sits
inside the internal gear, and the gears rotate in the same direction. Because the
shafts are positioned closer together, internal gear assemblies are more compact
than external gear assemblies. Internal gears are primarily used for planetary gear
drives.

Spur gears are generally seen as best for applications that require speed reduction
and torque multiplication, such as ball mills and crushing equipment. Examples of
9
high-speed applications that use spur gears – despite their high noise levels –
include consumer appliances such as washing machines and blenders. And while
noise limits the use of spur gears in passenger automobiles, they are often used in
aircraft engines, trains, and even bicycles.Spur gears are the most easily visualized
common gears that transmit motion between two parallel shafts. Because of their
shape, they are classified as a type of cylindrical gears. Since the tooth surfaces of
the gears are parallel to the axes of the mounted shafts, there is no thrust force
generated in the axial direction. Also, because of the ease of production, these
gears can be made to a high degree of precision. On the other hand, spur gears
have a disadvantage in that they easily make noise. Generally speaking, when two
spur gears are in mesh, the gear with more teeth is called the “gear” and the one
with the smaller number of teeth is called the “pinion”.

The unit to indicate the sizes of spur gears is commonly stated, as specified by
ISO, to be “module”. In recent years, it is usual to set the pressure angle to 20
degrees. In commercial machinery, it is most common to use a portion of an
involute curve as the tooth profile.

Even though not limited to spur gears, profile shifted gears are used when it is
necessary to adjust the center distance slightly or to strengthen the gear teeth. They
are produced by adjusting the distance between the gear cutting tool called the
hobbing tool and the gear in the production stage. When the shift is positive, the
bending strength of the gear increases, while a negative shift slightly reduces the
center distance. The backlash is the play between the teeth when two gears are
meshed and is needed for the smooth rotation of gears. When the backlash is too
large, it leads to increased vibration and noise while the backlash that is too small
leads to tooth failure due to the lack of lubrication.

All spur gears have an involute tooth shape. In other words, they are involute gears
using part of the involute curve as their tooth forms. Looking generally, the
10
involute shape is the most wide-spread gear tooth form due to, among other
reasons, the ability to absorb small center distance errors, easily made production
tools simplify manufacturing, thick roots of the teeth make it strong, etc. Tooth
shape is often described as a specification in drawing of a spur gear as indicated by
the height of teeth. In addition to standard full depth teeth, extended addendum and
stub tooth profiles exist.

3.1.Dimension Specifications
Gears mate via teeth with very specific geometry. Pitch is a measure of tooth
spacing and is expressed in several ways.

11
 Diametral pitch (DP) is the ratio of the number of teeth to the pitch
diameter of a gear; a higher DP therefore indicates finer tooth spacing. It is easily
calculated by the formula DP= (N+2) ÷ OD, where N is the number of teeth, and
OD represents the circumferential measurement.

Circular pitch (CP) is a direct measurement of the distance from one tooth
center to the adjacent tooth center. It can be measured by the formula CP= Π ÷
DP.

Module (M) is a typical gear discipline and is a measurement of the size and
teeth number of the gear. Gears measured in inches earn 'English module'
distinction to prevent confusion. M = OD ÷ N

Pressure angle is the angle of tooth drive action, or the angle between the
line of force between meshing teeth and the tangent to the pitch circle at the point
of mesh. Typical pressure angles are 14.5° or 20°.

12
 Gears must have the same pitch and pressure angle in order to mesh. Spur
gears do not have helix angles.

3.2.Mounting Specifications
Consider the gear center, bore diameter and shaft diameter. The gear center
can be a bored hole or an integral shaft. The bore diameter is the diameter of the
center hole. The shaft diameter is the diameter of the shaft for gears with an
integral shaft. Helical gears can be mounted on a hub or shaft. A hub is a
cylindrical projection on one or both sides of a helical gear, often for the provision
of a screw or other shaft attachment mechanism. Hubless gears are typically
attached via press fit, adhesive or internal keyway.

13
 3.3.Spur Gear Materials
Gear composition is determined by application, including the gear's service,
rotation speed, accuracy and more.

• Cast iron provides durability and ease of manufacture.

• Alloy steel provides superior durability and corrosion resistance. Minerals may
be added to the alloy to further harden the gear.
• Cast steel provides easier fabrication, strong working loads and vibration
resistance.
• Carbon steels are inexpensive and strong, but are susceptible to corrosion.
• Aluminum is used when low gear inertia with some resiliency is required.
• Brass is inexpensive, easy to mold and corrosion resistant.
• Copper is easily shaped, conductive and corrosion resistant. The gear's strength
would increase if bronzed.
• Plastic is inexpensive, corrosion resistant, quiet operationally and can
overcome missing teeth or misalignment. Plastic is less robust than metal and is
vulnerable to temperature changes and chemical corrosion. Acetal, delrin,
nylon, and polycarbonate plastics are common.
• Other material types like wood may be suitable for individual applications.
Spur gears are the most easily visualized common gears that transmit motion
between two parallel shafts. Because of their shape, they are classified as a type
of cylindrical gears. Since the tooth surfaces of the gears are parallel to the axes
of the mounted shafts, there is no thrust force generated in the axial direction.
Also, because of the ease of production, these gears can be made to a high
degree of precision. On the other hand, spur gears have a disadvantage in that
they easily make noise. Generally speaking, when two spur gears are in mesh,
the gear with more teeth is called the “gear” and the one with the smaller
number of teeth is called the “pinion”.

14
The unit to indicate the sizes of spur gears is commonly stated, as specified by
ISO, to be “module”. In recent years, it is usual to set the pressure angle to 20
degrees. In commercial machinery, it is most common to use a portion of an
involute curve as the tooth profile.

Even though not limited to spur gears, profile shifted gears are used when it is
necessary to adjust the center distance slightly or to strengthen the gear teeth. They
are produced by adjusting the distance between the gear cutting tool called the
hobbing tool and the gear in the production stage. When the shift is positive, the
bending strength of the gear increases, while a negative shift slightly reduces the
center distance. The backlash is the play between the teeth when two gears are
meshed and is needed for the smooth rotation of gears. When the backlash is too
large, it leads to increased vibration and noise while the backlash that is too small
leads to tooth failure due to the lack of lubrication.

All spur gears have an involute tooth shape. In other words, they are involute gears
using part of the involute curve as their tooth forms. Looking generally, the
involute shape is the most wide-spread gear tooth form due to, among other
reasons, the ability to absorb small center distance errors, easily made production
tools simplify manufacturing, thick roots of the teeth make it strong, etc. Tooth
shape is often described as a specification in drawing of a spur gear as indicated by
the height of teeth. In addition to standard full depth teeth, extended addendum and
stub tooth profiles exist.

3.4.Applications

• Inertia of the gear through acceleration and deceleration. Heavier gears can
be harder to stop or reverse.
• Precision requirement of gear, including gear pitch, shaft diameter, pressure
angle and tooth layout.

15
• Gear lubrication requirements. Some gears require lubrication for smooth,
temperate operation.
• Mounting requirements. Application may limit the gear's shaft positioning.
• Noise limitation. Commercial applications may value a smooth, quietly
meshing gear. Spur gears are particularly noisy in operation.
• Corrosive environments. Gears exposed to weather or chemicals should be
especially hardened or protected.
• Temperature exposure. Some gears may warp or become brittle in the face
of extreme temperatures.
• Vibration and shock resistance. Heavy machine loads or backlash, the
deliberate surplus space in the circular pitch, may jostle gearing.
• Operation disruption resistance. It may be necessary for some gear sets to
function despite missing teeth or misalignment.

16
 CHAPTER 4

METHODOLOGY

SOFTWARES USED

➢ Solidworks (for modelling the component)

➢ Ansys workbench (for analyzing the component)

17
 CHAPTER 5

SOLID WORKS 2018

SolidWorks (stylized as SOLIDWORKS), is a solid modeling computer-

aided design (CAD) and computer-aided engineering (CAE) software program that
runs on Microsoft Windows. The SolidWorks is produced by the DASSAULT
SYSTÈMES— a subsidiary of DassaultSystèmes, S. A. based in Velizy, France—
since 1997. SolidWorks is currently used by over 2 million engineers and designers
at more than 165,000 companies worldwide. In 2011–12, the fiscal revenue for
SolidWorks was reported $483 million.

We are using solid works 2018 for the 3D modelling of the spur gear.The
solid works is an effective design tool used to create the various design models.The
solid works part diagram is saved as ‘.sldprt’ format if we want to import the same
file in the ANSYS means we have to convert the .sldprt file into .step file.

MODELLING IN SOLID WORKS

18
 FINITE ELEMENT METHOD

5.1 Introduction to finite element method:

The finite element method is a powerful tool to obtain the numerical

solution of wide range of engineering problem. The method is general enough to
handle any complex shape or geometry, for any material under different boundary
and loading conditions. The generality of the finite element method fits the
analysis requirement of today’s complex engineering systems and designs where
closed form solutions of governing equilibrium equations are usually not available.
In addition, it is an efficient design tool by which designers can perform parametric
design studies by considering various design cases, (different shapes, materials,
loads, etc.) and analyze them to choose the optimum design.

The method originated in the aerospace industry as a tool to study stress in a

complex airframe structure. It grows out of what was called the matrix analysis
method used in aircraft design. The method has gained increased popularity among

19
both researchers and practitioners. The basic concept of finite element method is
that a body or structure may be divided into small elements of finite dimensions
called “finite elements”. The original body or the structure is then considered, as an
assemblage of these elements connected at a finite number of joints called nodes or
nodal points.

5.2. General procedure of finite element method:

The finite element method is a method of piecewise approximation in

which the structure or body is divided into small elements of finite dimensions
called finite elements and then the original body or the structure is considered as an
assemblage of these elements connected at finite number of joints called nodal
points or nodes. Since the actual variation of field variables like displacement,
stress, temperature, pressure or velocity inside the continuum are not known, the
variation of the field variable inside a finite element can be approximated by a
simple function. These approximation functions called interpolation models are
defined in terms of the values of the field variables of the nodes. The nodal values
of the field variable are obtained by solving the field equations, which are
generally in the form of matrix equations.

Once the nodal values are known, the approximating functions define the field
variable throughout the assemblage of elements.

The solutions of general continuum problems by the finite element method

always follow an orderly step-by-step process.

The step-by-step procedure for static structural problem can be stated as

follows:

Step 1: - Description of Structure (Domain). The first step in the finite element
method is todivide the structure of solution region in to sub divisions or elements.

20
Step 2: - Selection of proper interpolation model. Since the displacement (field
variable) solutionof a complex structure under any specified load conditions cannot
be predicted exactly, we assume some suitable solution, within an element to
approximate the unknown solution. The assumed solution must be simple and it
should satisfy certain convergence requirements.

Step 3: - Derivation of element stiffness matrices (characteristic matrices) and load

vectors. Fromthe assumed displacement model the stiffness matrix [K(e)] and the
load vector P(e) of element ‘e’ are to be derived by using either equilibrium
conditions or a suitable Variation principle.

Step 4: - Assemblage of element equations to obtain the equilibrium equations.

Since the structure is composed of several finite elements, the individual

element stiffness matrices and load vectors are to be assembled in a suitable
manner and the overall equilibrium equation has to be formulated as

[K]φ = P

Where [K] is called assembled stiffness matrix, Φ is called the vector of

nodal displacement and P is the vector or nodal force for the complete structure.

Step 5: - Solution of system equation to find nodal values of displacement (field

variable). Theoverall equilibrium equations have to be modified to account for the
boundary conditions of the problem. After the incorporation of the boundary
conditions, the equilibrium equations can be expressed as,

[K]φ = P

For linear problems, the vector ‘φ’ can be solved very easily. But for non-
linear problems, the solution has to be obtained in a sequence of steps, each step
involving the modification of the stiffness matrix [K] and ‘φ’ or the load vector P.

Step 6: - Computation of element strains and stresses. From the known nodal
displacements, ifrequired, the element strains and stresses can be computed by
21
using the necessary equations of solid or structural mechanics. In the above steps,
the words indicated in brackets implement the general FEM step-by-step
procedure.

Convergence requirement:

The finite element method provides a numerical solution to a complex

problem. It may therefore be expected that the solution must converge to the exact
formulation of the structure. Hence as the mesh is made finer the solution should
converge to the correct result and this would be achieved if the following three
conditions were satisfied by the assumed displacement function.

1. The displacement function must be continuous within the element. Choosing

polynomials for the displacement model can easily satisfy this condition.
2. The displacement function must be capable of representing rigid body
displacement of the element. This is when the nodes are given such
displacement corresponding to a rigid body motion; the element should not
experience and hence leads to zero nodal forces. The constant terms in the
polynomials used for displacement models would usually ensure this condition.
3. The displacement function must be capable of representing constant strain states
within the element. The reason for the requirement can be understood if we
imagine the condition when the body or structure is divided in to smaller and
smaller elements. As these elements approach infinitesimal size the strain in
each element also approach constant strain states. For one, two and three-
dimensional elasticity problems the linear terms present in the polynomials
satisfy the requirement. However, in constant curvature instead of constant
strains.
Advantages of FEM:

The properties of each element are evaluated separately, so an obvious

advantage is that we can incorporate different material properties for each element.

22
Thus, almost any degree of non-homogeneity can be included. There is no
restriction on to the shape of medium; hence arbitrary and irregular shapes
because no difficulty like all numerical approximations FEM is based on the
concept of description. Nevertheless, as either the variations or residual approach,
the technology recognizes the multidimensional continuous but also requires no
separate interpolation process to extend the approximate solution to every point
with the continuum.One of the important advantages of FEM is that it makes use of
boundary conditions in the form of assembled equations. This is relatively an easy
process and requires no special technology. Rather than requiring every trial
solution to satisfy boundary conditions, one prescribes the conditions after
obtaining the algebraic equations for individual’s finite elements.

Limitations in FEM:

FEM reached high level of development as solution technology; however the

method yields realistic results only if coefficient or material parameters that
describe basic phenomena are available.

The most tedious aspects of use of FEM are basic process of sub-dividing
the continuum of generating error free input data for computer.

Applications of FEM:

The finite element method was developed originally for the analysis of
aircraft structures. However, the general nature of its theory makes it applicable to
wide variety of boundary value problem in engineering. A boundary value problem
is one in which a solution is sought in domain or region of a body subject to the
satisfaction of prescribed boundary conditions.

Finite element method is the best tool in investigation of aircraft structures

involving static analysis of wings, structures of rockets and missiles, dynamic
analysis, response to random loads and periodic loads. In mechanical design, stress

23
concentration problems, stress analysis of pressure vessels, dynamic analysis of
mechanical linkages can be effectively dealt using finite element method.

The specific application of the finite element method in the three major
categories of boundary value problems, namely equilibrium of steady state or time
independent problems, Eigen value problems, and propagation or transient
problems. In the equilibrium problems steady state displacement or stress
distribution is found for a solid mechanics problem, temperature or heat flux
distribution in the case of heat transfer problem. Referring to Eigen value problems
in solid mechanics or structural problem, natural frequencies, buckling loads and
mode shapes are found, stability of laminar flows is found if it is a fluid mechanics
problem and resonance characteristics are obtained if it is an electrical circuit
problem, while for the propagation or transient problem, the response of the body
under time varying force is found in the area of solid mechanics.

Finite element method finds its application in the field of civil engineering in
carrying out the static analysis of trusses, frames and bridges. The dynamic
analysis of the structure is to obtain natural frequencies, modes and response of the
structures to periodic loads. Nuclear engineering also uses finite element method
concept in the static and dynamic characterization of its systems such as nuclear
pressure vessels, containment structure and dynamic response of reactor
component containment structures. Even the Biomedical engineering applies finite
element method, for impact analysis of skulls. Finite element method can be
applied to analysis of excavation, underground openings and dynamic analysis of
dam reservoir systems, which come under Geo-mechanics

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 CHAPTER 6
FEA SOFTWARE – ANSYS

6.1 Introduction to ANSYS Program:

Dr. John Swanson founded ANSYS. Inc. in 1970 with a vision to

commercialize the concept of computer simulated engineering, establishing
himself as one of the pioneers of Finite Element Analysis (FEA). ANSYS Inc.
supports the ongoing development of innovative technology and delivers flexible,
enterprise wide engineering systems that enable companies to solve the full range
of analysis problem, maximizing their existing investments in software and
hardware. ANSYS Inc. continues its role as a technical innovator. It also supports a
process-centric approach to design and manufacturing, allowing the users to avoid
expensive and time-consuming “built and break” cycles. ANSYS analysis and
simulation tools give customers ease-of use, data compatibility, multi-platform
support and coupled field multi-physics capabilities.

6.2 Evolution of ANSYS Program:

ANSYS has evolved into multipurpose design analysis software program,

recognized around the world for its many capabilities. Today the program is
extremely powerful and easy to use. Each release hosts new and enhanced
capabilities that make the program more flexible, more usable and faster. In this
way ANSYS helps engineers meet the pressures and demands modern product
development environment.

6.3 Overview of the program:

The ANSYS program is flexible, robust design analysis and optimization

package. The software operates on major computers and operating systems, from

26
 PCs to workstations and to super computers. ANSYS features file compatibility
throughout the family of products and across all platforms. ANSYS design data
access enables user to import computer aided design models in to ANSYS,
eliminating repeated work. This ensures enterprise wide, flexible engineering
solution for all ANSYS user.

User Interface: Although the ANSYS program has extensive and complex
capabilities, itsorganization and user-friendly graphical user interface makes it easy
to learn and use.

There are four graphical methods to instruct the ANSYS program:

1.Menus
2.Dialog Boxes
3.Tool bar
4.Direct input of commands.
Menus: Menus are groupings of related functions or operating the analysis
program located inindividual windows. These include:

1. Utility menu
2. Main menu
3. Input window
4. Graphics window
5. Tool bar
6. Dialog boxes
Dialog boxes: Windows that present the users with choices for completing the
operations orspecifying settings. These boxes prompt the user to input data or
make decisions for a particular function.

27
Tool bar: The tool bar represents a very efficient means for executing commands
for theANSYS program because of its wide range of configurability. Regardless of
how they are specified, commands are ultimately used to supply all the data and
control all program functions.

Output window: Records the ANSYS response to commands and functions

Graphics window: Represents the area for graphic displays such as model or
graphicallyrepresented results of an analysis. The user can adjust the size of the
graphics window, reducing or enlarging it to fit to personal preferences.

Input window: Provides an input area for typing ANSYS commands and displays
programprompt messages.

Main menu: Comprise the primary ANSYS functions, which are organized in
pop-up sidemenus, based on the progression of the program.

Utility menu: Contains ANSYS utility functions that are mapped here for access
at any timeduring an ANSYS session. These functions are executed through
smooth, cascading pull down menus that lead directly to an action or dialog box

Database: The ANSYS program uses a single, centralized database for all model
data andsolution results. Model data (including solid model and finite element
model geometry, materials etc.) are written to the database using the processor.
Loads and solution results data are written using the solutions processor. Post
processing results data are written using the post processors. Data written to the
database while using one processor are therefore available as necessary in the other
processors.

File format: Files are used, when necessary, to pass the data from part of the
program to another,to store the program to the database, and to store the program

28
output. These files include database files, the results file, and the graphics file and
so on.

6.4 Reducing the design and manufacturing costs using ANSYS (FEA):

The ANSYS program allows engineers to construct computer models or

transfer CAD models of structures, products, components, or systems, apply loads
or other design performance conditions and study physical responses such as stress
levels, temperature distribution or the impact of vector magnetic fields. In some
environments, prototype testing is undesirable or impossible. The ANSYS program
has been used in several cases of this type including biomechanical applications
such as hi replacement intraocular lenses. Other representative applications range
from heavy equipment components, to an integrated circuit chip, to the bit-holding
system of a continuous coal-mining machine. ANSYS design optimization enables
the engineers to reduce the number of costly prototypes, tailor rigidity and
flexibility to meet objectives and find the proper balancing geometric
modifications. Competitive companies look for ways to produce the highest quality
product at the lowest cost. ANSYS (FEA) can help significantly by reducing the
design and manufacturing costs and by giving engineers added confidence in the
products they design. FEA is most effective when used at the conceptualdesign
stage. It is also useful when used later in manufacturing process to verify the final
design before prototyping.

6.5 Program availability

The ANSYS program operates on Pentium based PCs running on

Wndows95 or Windows NT and workstations and super computers primarily
running on UNIX operating system. ANSYS Inc. continually works with new
hardware platforms and operating systems.

29
6.6 Analysis types available:

1. Structural static analysis.

2. Structural dynamic analysis.
3. Structural buckling analysis.
a) Linear buckling
b) Nonlinear buckling
4. Structural nonlinearity’s.
5. Static and dynamic kinematics analysis.
6. Thermal analysis.
7. Electromagnetic field analysis.
8. Electric field analysis
9. Fluid flow analysis
a) Computational fluid dynamics
b) Pipe flow
10.Coupled-field analysis
11.Piezoelectric analysis.
6.7 Procedure for ANSYS analysis:

Static analysis is used to determine the displacements, stresses, strains and

forces in structures or components due to loads that do not induce significant
inertia and damping effects. Steady loading in response conditions are assumed.
The kinds of loading that can be applied in astatic analysis include externally
applied forces and pressures, steady state inertial forces such as gravity or
rotational velocity imposed (non-zero) displacements, temperatures (for thermal
strain). A static analysis can be either linear or nonlinear. In our present work we
consider linear static analysis.

30
The procedure for static analysis consists of these main steps:

1. Building the model.

2. Obtaining the solution.
3. Reviewing the results.
Build the model:

In this step we specify the job name and analysis title use PREP7 to define
the element types, element real constants, material properties and model geometry
element types both linear and non-linear structural elements are allowed. The
ANSYS element library contains over 80 different element types. A unique
number and prefix identify each element type. E.g. BEAM 3, PLANE 55, SOLID
45 and PIPE 16.

Material properties:

Young’s modulus (EX) must be defined for a static analysis. If we plan to

apply inertia loads (such as gravity) we define mass properties such as density
(DENS). Similarly, if we plan to apply thermal loads (temperatures) we define
coefficient of thermal expansion (ALPX).

Obtain the solution:

In this step we define the analysis type and options, apply loads and initiate the
finite element solution. This involves three phases:

a) Pre-processor
b) Solution
c) Post processor

31
Pre – Processor:

Preprocessor has been developed so that the same program is available on

micro, mini, super-mini and mainframe computer system. This slows easy transfer
of models one system to other. Preprocessor is an interactive model builder to
prepare the FE (finite element) model and input data. The solution phase utilizes
the input data developed by the preprocessor, and prepares the solution according
to the problem definition. It creates input files to the temperature etc., on the screen
in the form of contours.

6.7 Geometrical definitions:

There are four different geometric entities in preprocessor namely key

points, lines, areas and volumes. These entities can be used to obtain the geometric
representation of the structure. All the entities are independent of other and have
unique identification labels.

6.8 Model generations:

Two different methods are used to generate a model:

a) Direct generation.
b) Solid modeling
With solid modeling we can describe the geometric boundaries of the model,
establish controls over the size and desired shape of the elements and then instruct
ANSYS program to generate all the nodes and elements automatically. By contrast,
with the direct generationmethod, we determine the location of every node and
size, shape and connectivity of every element prior to defining these entities in the
ANSYS model. Although, some automatic data generation is possible (by using
commands such as FILL, NGEN, EGEN etc.) the direct generation method
essentially a hands-on numerical method that requires us to keep track of all the
32
node numbers as we develop the finite element mesh. This detailed book keeping
can become difficult for large models, giving scope for modeling errors. Solid
modeling is usually more powerful and versatile than direct generation and is
commonly preferred method of generating a model.

6.9 Mesh generation:

In the finite element analysis, the basic concept is to analyze the structure,
which is an assemblage of discrete pieces called elements, which are connected,
together at a finite number of points called Nodes. Loading boundary conditions
are then applied to these elements and nodes. A network of these elements is
known as Mesh.

6.10 Finite element generation:

The maximum amount of time in a finite element analysis is spent on

generating elements and nodal data. Preprocessor allows the user to generate nodes
and elements automatically at the same time allowing control over size and number
of elements. There are various types of elements that can be mapped or generated
on various geometric entities.

The elements developed by various automatic element generation

capabilities of preprocessor can be checked element characteristics that may need
to be verified before the finite element analysis for connectivity, distortion-index,
etc. Generally, automatic mesh generating capabilities of preprocessor are used
rather than defining the nodes individually. If required, nodes can be defined easily
by defining the allocations or by translating the existing nodes. Also one can plot,
delete, or search nodes.

33
Boundary conditions and loading:

After completion of the finite element model it has to constrain and load has
to be applied to the model. User can define constraints and loads in various ways.
All constraints and loads are assigned set 1D. This helps the user to keep track of
load cases.

6.11 Model display:

During the construction and verification stages of the model it may be

necessary to view it from different angles. It is useful to rotate the model with
respect to the global system and view it from different angles. Preprocessor offers
this capability. By windowing feature preprocessor allows the user to enlarge a
specific area of the model for clarity and details. Preprocessor also provides
features like smoothness, scaling, regions, active set, etc. for efficient model
viewing and editing.

6.12 Material definitions:

All elements are defined by nodes, which have only their location defined.
In the case of plate and shell elements there is no indication of thickness. This
thickness can be given as element property. Property tables for a particular
property set 1-D have to be input. Different types of elements have different
properties for e.g. Beams: Cross sectional area, moment of inertia etc. Shells:
Thickness Springs: Stiffness Solids: None

The user also needs to define material properties of the elements. For linear static
analysis, modules of elasticity and Poisson’s ratio need to be provided. For heat
transfer, coefficient of thermal expansion, densities etc. are required. They can be
given to the elements by the material property set to 1-D.

34
6.13 Solution:

The solution phase deals with the solution of the problem according to the
problem definitions. All the tedious work of formulating and assembling of
matrices are done by the computer and finally displacements and stress values are
given as output. Some of the capabilities of the ANSYS are linear static analysis,
non-linear static analysis, transient dynamic analysis, etc.

35
 CHAPTER 7

ANSYS PROCEDURE

I coefficient of friction= 0.1

1. Import the geometryfile in ANSYS

36
2. Load applied on gear

3. Total deformation

37
4. Elastic strain

5. Stress

38
II Frictional co-efficient = 0.2

1. Total deformation

2. Elastic strain

39
3. Stress

III Frictional coefficient =0 .3

1. Total deformation

40
2. Elastic strain

3. Stress

41
Results

1. For frictional coefficient 0.1

2. For frictional coefficient 0.2

3. For Friction coefficient 0.3

42
 CHAPTER 8

CONCLUSION

Based on the design and analysis process the following conclusions are
obtained

• The presented FE model results have a high degree of coincidence withthe

theoretical results, hence the model proved to be suitable in the analysis of
active contact stresses on the tooth flanks of a gear pair.
• The contact stress calculated for different coefficient of friction showed that
the contact stress increased with increasing value of static coefficient of
friction. A 10% rice has been observed when the friction coefficient value
was increased from 0.1 from 0.3
• The increase in the contact stress with the increase in friction coefficient
provides with an idea of friction coefficient provides with a friction factor to
be incorporated while calculating the contact stress in meshed gears.

43
 CHAPTER 9

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• Lias MR, TVVLN R, Awang M, Khan MA. The stress distribution of gear
tooth
due to axial misalignment condition. Journal of Applied Sciences. 2012 Dec
1;12(23):2404-10.
• Guo Y, Lambert S, Wallen R, Errichello R, Keller J. Theoretical and
experimental
study on gear-coupling contact and loads considering misalignment, torque,
and
friction influences. Mechanism and Machine Theory. 2016 Apr 30;98:242-
62.
• Ali SM, Mohammad OD. Load sharing on spur gear teeth and stress analysis
when
contact ratio changed. Eng. Tech. J. 2008;16:94-101.
• Hassan AR. Contact stress analysis of spur gear teeth pair. World Academy
of
Science, Engineering and Technology. 2009; Oct 20: 58 (1):597-602.
• Li S, Anisetti A. A tribo-dynamic contact fatigue model for spur gear pairs.
International Journal of Fatigue. 2017 May 1;98:81-91.
• Patil SS, Karuppanan S, Atanasovska I. Contact stress evaluation of involute
gear pairs, including the effects of friction and helix angle. Journal of
Tribology. 2015 Oct 1; 137(4):044501. Patil SS, Karuppanan S,

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• Atanasovska I, Wahab AA. Contact stress analysis of
helical gear pairs, including frictional coefficients. International Journal of
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