Aim

• In this project, the parametric design modelling and failure analysis of spur gear will be
investigated. The three  dimensional solid model will be generated in Solid Works software, the
model of spur gear will be imported in ANSYS software and then failure modes will be analyzed
in ANSYS.
Methodology
1. Design:
The modelling of the gear will be done in Solid Works.

2. Meshing & Analysis :

The meshing of the designed component will be done in Ansys. Later, Initial loading Conditions will be
applied and the analysis will be done in 2 different cases.

• CASE I – The material of the gear will be assumed as Carbon steel and the analysis will be done.
• CASE II – Holes will be introduced in the gear to reduce the stress and the analysis will be done.

3. Result Analysis and Conclusion:

From the results obtained from the analysis of gear in two different cases, The optimum shape size and
location of the stress relieving holes will be determined to reduce failure.
Literature Survey
1. Design and analysis of spur gear
IAEME 2016
Pinaknath Dewanji, This paper analyses the bending stresses characteristics of an involute
spur gear tooth under static load conditions..
• Testing or analysis method used – modelling done in CATIA V5R20 software analysis done on
ANSYS 14.5 software
• Equipments/Tools used - CATIA V5R20 , ANSYS 14.5
• Result - The stress at the tooth root are evaluated analytically using existing theoretical models.
• Conclusion – The static and dynamic analysis of spur gear tooth helps to determine maximum
displacement,maximum induced stress and effect of stress variation with respect to time. The
loading capacity and operating speed of geared system can be increased by reducing the
maximum induced stresses.
2. Structural analysis of spur gear using FEM
IJMET 2016
Devender singh ., In this paper modeled the spur gear and study about gear drive design and
analysis is carried out with the help of pro-e and ansys and improve the static and dynamic
characteristics of gear drive.
• Testing or analysis method used – modelling done in Pro-e software analysis done on ANSYS
14.5 software
• Equipments/Tools used – Pro-e, ANSYS 14.5
• Result – Analysis results for spur gear in Ansys at static analysis and dynamic analysis were done
and comparision of both were done
• Conclusion -This project work focuses three dimensional spur gear analysis under both static and
dynamic conditions.The purpose of three-dimensional analysis is to predict the gear behavior on
real operating conditions.
3. Design and Analysis of Composite Spur Gear
IJRSI 2015
S.Mahendran, K.M.Eazhil , L.Senthil Kumar,This paper modeled the spur gear using solid
works software.The weight reduction and stress distribution for cast steel and composite materials
are studied. Finally compare and analyzing the spur gear using ANSYS software.
• Testing or analysis method used – modelling done in solid works software analysis done on
ANSYS 14.5 software
• Equipments/Tools used – solid works , ANSYS 14.5
• Result – Analysis results for spur gear in various materials, and reports for cast steel spur gear in
various torque
• Conclusion - The weight reduction and stress distribution for cast steel and composite materials
are studied
4. Bending stress analysis & optimization of spur gear
IJERT(2014)
Ram Krishna rathore & abhishek Tiwari., In this paper the process and the important
phenomena of Bending Stress and its fatigue life has discussed. This paper offers a unique and
comprehensive process for the design and optimization of Spur gear bending stress and related fatigue
life. By the means of stress relief features we can reduce the bending stress and increase the fatigue life
of spur gear, but along with this we discussed about the optimization of the Bending stress and fatigue
life with respect to the size and location parameters of the stress relief holes.
• Testing or analysis method used – analysis done on ANSYS 14.5 software
• Equipments/Tools used – ANSYS 14.5
• Result – This work presents the results obtained by applying analytical method (AGMA) for spur gear
to calculate the bending stress and the same by FEA analyses, which shows a good result in
comparison.
• Conclusion - The introduction of a elliptical hole or circular hole on the dedendum circle reduces the
stress levels by a very high percentage with a small loss of rigidity of the tooth. This translates into an
exponential increase in the life of the gear due to a better location on the S-N curve for fatigue loading.
5. Modernization of Main Helicopter Gearbox with Asymmetric Tooth Gears
IDETC/CIE2013
IGOR L.GLIKSON & ALEXANDER A.STUPAKOV, This paper describes the research
and development of asymmetric tooth spur gears for modernization of the light multipurpose
helicopter gearbox amplifying its load capacity to utilize more powerful turboshaft engines.The
paper also presents numerical design data related to development this gearbox
• Testing or analysis method used – ANSYS 14.5 software
• Equipments/Tools used – ANSYS 14.5
• Result – Replacement the originally used spur symmetric tooth gears for the gears with
asymmetric teeth allowed to utilized more powerful and fuel efficient turboshaft engines without
complete redesign of the helicopter gearbox
• Conclusion – The modernization of main helicopter gearbox with asymmetric tooth gears are
done and fuel efficiency of the engine increases
6. Finite Element Analysis of a Spur Gear Tooth Using Solid Works
Simulation And Stress Reduction By Stress Relief Hole
IJERT (2012)
Vivek Singh, Sandeep Chauhan, In this paper the analysis stress reduction is discussed by
means of introducing stress relieving feature. A careful selection of more than one location for
introducing stress relieving feature is more beneficial than choosing only one. Stress reductions by
means of introducing circular stress reliving features are found to be better.
• Testing or analysis method used – analysis done on ANSYS 14.5 software
• Equipments/Tools used – ANSYS 14.5
• Result – It is found that the maximum principal stress at root fillet is 43.2 Mpa without any stress
relieving features. Various cases are considered for analysis choosing different values of hole
position and diameter. Analysis reveals that the case with a circular hole having 3mm. diameter
and 4mm. distance from root circle shows the greater benefit in comparison with other cases by
reducing stress at root fillet to 24.8 Mpa.
• Conclusion - As per analysis stress reduction by means of introducing stress reliving feature is
possible. The redistribution is highly sensitive to the change in size of the stress relieving feature.
A careful selection of more than one location for introducing stress relieving feature is more
beneficial than choosing only one.Stress reductions by means of introducing circular stress
reliving features are found to be better.The circular stress relief feature have better controover
changing the stress redistribution pattern.
Work Completed
• Design parameters of spur gear with the help of gear ratio from the article and calculations were
done with the help of standard design data book.
• Design of pinion and gear completed as per the design parameters in solid works.
• Meshing of pinion and gear is done in ANSYS.
Work to be completed ( with time line plan)
• Analysis of the meshed pinion and gear for different loading conditions – 17/02/2021 to
15/03/2021
• Introducing holes in the existing model at different locations – 16/03/2021 to 02/04/2021
• Failure Analysis of gears with holes in ANSYS – 03/04/2021 to 10/04/2021
• Results and discussions to identify the optimum size and shape of stress relieving hole from the
analysis – 10/04/2021 to 14/04/2021
• Completion of Project-15/04/2021.
 Geometry/ Model/Set up

Isometric view of pinion and gear Meshing of pinion and gear

• Pinion and gear is designed in solid works
• Meshing is done in ANSYS
Input parameters for Meshing
• Display
Display style Use geometry setting

• Defaults
Physics preference mechanical
Element order Program controlled
Element size default
• statistics

nodes 1092237
elements 646370
Calculations of Spur Gear
For C45 steel
Standard gear ratio from table 4, page no 8.3
i=2.5 
ii) From table 10, page 8.14
Ψ= 0.3
 
iii) From table 9, For steel equivalent Young’s modulus,
Eeq =2.15 × 106 kg f/cm2
 iv) From table 7, page no 8.5
For C45 Steel, σb=1400 kgf/cm2 , σc=5000 kgf/cm2
 v) From table 18, page 8.18
Ƶ1=20 Teeth, Y=0.389 (Assumed)
 
•   From table 11, page 8.14
vi)
Ψm=10
vii) From table 26, page 8.22
Height Factor f0=1
From table 13, page 8.15
Design twisting moment [Mt]=Mt.Kd.k
Power(P)=470hp
Speed(n)=667 rpm
Mt=71620
Design twisting moment [Mt]= 71620 × × 1.3
[Mt] = 65606.9265 kgf/cm2
• 
 Minimum centre distance based on surface compressive strength,
Page 8.13, Formula no – 1.1 (PSG Data book)
 
 
Centre distance (a) = (I ± 1)
 
= (2.5+1)

= 56.1071 cm
Take the nearest centre distance, 60 cm
a =60cm
• 
Minimum module (m) = 1.26
= 1.26
= 1.0641cm
Take the nearest module, 1.06 cm or 10.6 mm
m= 1.06cm = 10.6mm
Number of teeth (Ƶ)
Ƶ1 = =
 
Ƶ1= 32.3450
Take the nearest value
Ƶ1 = 33 Teeth
Ƶ2 = I × Ƶ1 = 2.5 × 33 = 82.5
Ƶ2 = 83 Teeth
•   Circle Diameter (d)
Pitch
d1 = m × Ƶ1 = 1.06 × 33 = 34.98 cm
d2 = m × Ƶ2 = 1.06 × 83 = 87.98 cm
Corrected Centre Distance (ac) =
= =
= 61.48cm
Take the nearest highest value ac = 63 cm
acorrected > amin
The design is safe.
Face Width (b) = Ψm × m
= 10 × 1.06
b = 10.6cm
and also,
Face Width (b) = Ψ × ac
b = 0.3 × 63
b = 18.9 = 19cm (Taking Highest Value)
Taking Nearest Value to the highest value
Face Width (b) = 19 cm
tooth Depth (h) = 2.25 × m
= 2.25 × 1.06
h = 2.5 = 25mm
Bottom Clearance (c) = 0.25 × m
= 0.25 × 1.06
c = 0.265cm = 26.5mm
Tip Diameter (da) Height Factor(f0) = 1
da1 = (Ƶ1+2f0)m
= (33 + 2(1)) 1.06
da1 = 37.1cm
da2 = (Ƶ2+2f0)m
=(83+2(1)) 1.06
= 90.1 cm
 
 Root Diameter (df)
 
df1 = (Ƶ1-2f0) m-2C
= (33-2(1)) 1.06-2(2.65)
df1 = 27.56cm
 
df2 = (Ƶ2-2f0) m-2C
= (83-2(1)) 1.06 – 2(2.65)
= 37.2 – 0.2
df2 = 80.56cm
 
•   CHECKING
FOR
σc = 0.74 ×
σc = 0.74 ×
σc = 4191.220487 Kg f/cm2 is less than [σc], so the design is safe.

σb = [
= × [2940.1894]

σb = 465.2584 kg f/cm2, is less than [σb], so the design is safe.

 
Calculations of Spur Gear
For Case Hardened (40Ni 2 Cr1 Mo Mo28) steel
i)Gear ratio from article [ref2]
i=2.5
ii) From table 10, page 8.14
Ψ= 0.3 
iii) From table 9, For steel equivalent Young’s modulus,
Eeq =2.15 × 106 kg f/cm2
iv) From table 7, page no 8.5
For Case Hardened Steel, σb=4000 kgf/cm2 , σc=11000 kgf/cm2
v) From table 18, page 8.18
Ƶ1=20 Teeth, Y=0.389 (Assumed)
 
•   From table 11, page 8.14
vi)
Ψm=10

vii) From table 26, page 8.22

Height Factor f0=1

From table 13, page 8.15

Design twisting moment [Mt]=Mt.Kd.k
Power(P)=470hp
Speed(n)=667 rpm
Mt=71620  
Design twisting moment [Mt]= 71620 × × 1.3
[Mt] = 65606.9265 kgf/cm2
• 
Minimum centre distance based on surface compressive strength,
Page 8.13, Formula no – 1.1 (PSG Data book)
Centre distance (a) = (I ± 1)
= (2.5+1)
= 32.5722 cm
Take the nearest centre distance, 33 cm
a=33cm
Minimum module (m) = 1.26
= 1.26
= 0.7499cm
Take the nearest module, 0.8 cm or 8 mm
m= 0.9cm = 9mm
 
• 
Number of teeth (Ƶ)
Ƶ1= =
 
Ƶ1= 23.5714
Take the nearest value
Ƶ1 = 25 Teeth
Ƶ2 = I × Ƶ1 = 2.5 × 25 = 62.5
Ƶ2 = 65 Teeth
 
Pitch Circle Diameter (d)
d1 = m × Ƶ1 = 0.8 × 25 = 20 cm
d2 = m × Ƶ2 = 0.8 × 65 = 58.5 cm
 
 
•Corrected
  Centre Distance (ac) =
=
= 39.5cm
Take the nearest highest value ac = 40cm
acorrected > amin
The design is safe.
Face Width (b) = Ψm × m
= 10 × 0.8
b = 8cm
and also,
Face Width (b) = Ψ × ac
b = 0.3 × 40
b = 12 cm (Taking Highest Value)
Taking Nearest Value to the highest value
Face Width (b) = 12 cm
Tooth Depth (h) = 2.25 × m
= 2.25 × 0.8
h = 1.8 cm = 18mm
Bottom Clearance (c) = 0.25 × m
= 0.25 × 0.8
c = 0.2cm = 2mm
Tip Diameter (da) Height Factor(f0) = 1
da1 = (Ƶ1+2f0)m
= (25 + 2(1)) 0.8
da1 = 21.6cm
da2 = (Ƶ2+2f0)m
=(65+2(1)) 0.8
= 53.6 cm
 
Root Diameter (df)
 df1 = (Ƶ1-2f0) m-2C
= (25-2(1)) 0.8-2(0.2)
df1 = 18cm
 
df2 = (Ƶ2-2f0) m-2C
= (65-2(1)) 0.8 – 2(0.2)
df2 = 50cm
 
•   CHECKING
FOR
σc = 0.74 ×
 
σc = 0.74 ×
 
σc = 8306.292949 Kg f/cm2 is less than [σc], so the design is safe.
 
 
σb = [
= × [2940.1894]

σb = 1537.22313 kg f/cm2, is less than [σb], so the design is safe.

References
1. Pinaknath Dewanji,”Design and analysis of spur gear” IAEME (2016)
2. Devender singh , “Structural analysis of spur gear using FEM”IJMET (2016)
3. S.Mahendran, K.M.Eazhil , L.Senthil Kumar, “Design and Analysis of Composite Spur Gear
“IJRSI (2015)
4. Ram Krishna rathore & abhishek Tiwari, “Bending stress analysis & optimization of spur gear”
IJERT(2014)
5. IGOR L.GLIKSON & ALEXANDER A.STUPAKOV “Modernization of Main Helicopter
Gearbox with Asymmetric Tooth Gears” IDETC/CIE(2013)
6. Vivek Singh, Sandeep Chauhan,“Finite Element Analysis Of A Spur Gear Tooth Using Solid
Works Simulation And Stress Reduction By Stress Relief Hole” IJERT (2012)
Thank you