Engineering Analysis and Design

Bending Stress Analysis &

Optimization of Spur Gear

Group-22
20117066 KARTIKEY SINGH

20117067 KAVETI SRINIVAS PARAMESHWAR

20117068 KESHAV MANDOWRA

20117069 KHUSHIRAM KUMAWAT

20117070 KINSHU KUMAR

20117071 KRITIKA
 Table of Contents

S. No. Topic Page no.

1. Acknowledgment 2
2. Abstract 3
3. Introduction 4-5
4. Computational Details 6-8
5. Results and Discussion 9-13
6. Conclusion 14
7. Contribution 15
8. Reference 16

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 Acknowledgment
We would like to express our deep and sincere gratitude to our supervisor,
Prof. Avinash Parashar, for providing invaluable guidance & suggestions
throughout the course of the project. His dynamism and vision inspired us and kept
us motivated.

We would also like to thank Dr. I. V. Singh and Prof. M.M. Joglekar for constantly
assisting us during the progress of the course on Engineering Analysis and Design.
They played an important role in teaching us the methodology to carry out our
analysis and present an academically refined project.

We are also grateful to our friends and family members for their cooperation and
support that helped us in the successful completion of the project despite the
various challenges and communication barriers in the online semester and the
challenging pandemic situation.

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 Abstract

Our project aims at reducing bending stresses on spur gears by using holes as stress
relief features by optimizing their size and distance from the center of the gear.

We designed a CAD model of spur gear with 20 teeth in Solidworks & performed
Finite Element Analysis in Ansys. Mesh convergence was used for better &
accurate results. After performing analysis on the CAD model of the original gear,
we created a single circular hole (stress relief feature) below the root of a tooth &
performed the same analysis. It was found that the resultant stress values were
reduced.

Further, we created a hole below each tooth & found that stress values were further
reduced. Next, we put constraints on i) diameter of the hole & ii) location of the
hole to optimize our results. It was observed that the bending stress is minimum
when the diameter of the hole is minimum, and the distance between the hole’s
center and shaft center is maximum.

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 Introduction

Gear is a mechanical element used to transmit power and motion by progressive

engagement of teeth. To overcome the problem of slipping and compactness faced
while using a belt-drive, chain drive, and other similar methods of power
transmissions, gears are employed which produce a positive drive with uniform
angular velocity. The main objective of the gear drive system is to transmit high
power with a smaller dimension of a driving system that can be fabricated with
minimum manufacturing cost and runs free of vibration and noise. So the design
should be economically sound and feasible. There is a wide variety of gear like
Spur gear, Helical gear, Bevel gear, Worm gear, etc.

Spur gear is a type of gear in which teeth are straight and are parallel to the wheel
axis. Here parallel and coplanar shafts are used to connect the gear. They are easy
to design, low maintenance, economical to manufacture, and they impose only
radial load on the bearings.

Spur gears of different sizes

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Finite Element Analysis is a numerical method for solving any complex real-life
system in engineering disciplines. It is a powerful tool for engineering analysis to
solve structural, biomechanics, electromagnetic field, linear static, and nonlinear
transient dynamic problems. FEA works with different levels of geometry
idealization and gives results with better accuracy. In recent trends, designing gears
has become a highly complicated subject in the area of machine design. So, it must
be accurate and rugged. There are several types of gear available, but the simplest
and widely used gears are the one which is used to transmit a determined speed
ratio between two parallel shafts at a defined distance.

Mesh Convergence determines how many elements are required in a model to

ensure that the results of an analysis are not affected by changing the size of the
mesh i.e. independent of the mesh quality.
Mesh refinement is the process of resolving the model with successively finer and
finer meshes, comparing the results between these different meshes.

We used two software during the course of our project-

SolidWorks is a solid modeler and utilizes a parametric feature-based approach to

create models and assemblies.

Structural analysis software from ANSYS provides the ability to simulate every
structural aspect of a product, including linear static analysis that simply provides
stresses or deformations, modal analysis that determines vibration characteristics,
advanced transient nonlinear phenomena involving dynamic effects, and complex
behaviors.

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 Computational Details

CAD model preparation in Solidworks

The industrial specifications of a 20-tooth spur gear were followed.

Global variables declared in the form of equations in Solidworks

Primary 2D sketch Final CAD Model of spur gear

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Static Structural Analysis in ANSYS
A constraint of fixed support was added to the gear & a tangential force of 25,000
N was applied after inserting stress, stress tool & fatigue tool in the solution
section.

Boundary Conditions

Next, a circular hole of arbitrary dimension was created at an arbitrary distance below the
root of the tooth, and a similar analysis was done.
Now we created 20 holes at equal distances, one below the root of each tooth.

Spur gear with a single hole Spur gear with a 20 holes

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Mesh Generation

We use two kinds of elements (Hybrid meshing) because the geometry varies
throughout the gear, and we want better from the tooth of the gear as compared to
the central body. The elements used for generating the mesh were –
1. Tetragonal, which has ten nodes. [ TET10 ]: the mesh requires essentially
no user effort as it has very small elements in the trace.
2. Quadrilateral, which has eight nodes. [ QUAD8 ]: allows a better
representation of a curved boundary.

Mesh

Mesh Convergence and Refinement

We specified an allowable change of 2% in the mesh convergence.

Convergence Conditions

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 Results and Discussion

Analysis of the original spur gear

A high-stress region was observed near the root of the gear. Correspondingly, the
minimum factor of safety and life was also obtained in the same region.

Tabulated results before convergence

In order to obtain mesh-independent results, we performed mesh convergence.

Convergence Curve

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 Tabulated results after convergence

Stress Contours Safety Factor Contours

Life Contours

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Analysis of spur gear with a single hole at the root
We created a circular hole at the root of the gear. It can be clearly observed that
there was an increase in the safety factor and fatigue life of the spur gear.

Tabulated results

Stress Contours Safety Factor Contours

Life Contours

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Analysis of spur gear with a hole at the root of each tooth
Now we further created 20 equidistant holes (18 degrees) and performed our analysis. It
was observed that the holes were an effective stress relief feature and significantly
increased the safety factor and fatigue life.

Tabulated results

Stress Contours Safety Factor Contours

Life Contours

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Parametrizing the hole size and distance
In order to optimize the results, we parametrized the hole diameter and the distance of the
holes from the center of the spur gear. The results obtained after the simulations were as
follows:

Parameter Table

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 Conclusion

As a part of our analysis, we observed that the maximum stress region occurs near
the root of the gear (i.e. between two teeth)

Holes at the root of the teeth in a spur gear act as great stress relief features.
Equally spaced holes at optimum distances provide the best results.

With the increase in the height of the holes from the center of the spur gear, the
stress value decreases.

With the increase in the diameter of the holes, the stress value is increasing.

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 Contribution

All the members participated enthusiastically in the project and contributed almost
equally towards its successful completion. The primary responsibilities and tasks
carried out by the members were as follows:

S No. NAME ROLL NO. CONTRIBUTION

1 Kartikey Singh 20117067 3D CAD Model

2 Kaveti Srinivas Parmeshwar 20117068 Mesh generation and analysis

of primary CAD model
3 Keshav Mandowra 20111024 Analysis of Spur gear with
holes
4 Khushiram Kumawat 20117069 2-D sketch of CAD model
5 Kinshu Kumar 20117070 Parametrization of hole
diameter and location
6 Kritika 20117071 Mesh Convergence

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 References

● All the members participated enthusia

https://www.youtube.com/watch?v=TAQvypaPcTA

https://youtu.be/9P-01CMfuQ4

https://youtu.be/XIR6R_mcY9s

https://my.solidworks.com/solidworks/guide/SOLIDWORKS_Introduction_EN.pdf

http://research.me.udel.edu/~lwang/teaching/MEx81/ansys56manual.pdf

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