Third review

Design and optimization of spur gear

Presented By:
18695A0327 K. Kiran Kumar
Supervised By: 18695A032
B.Yashwanth
Dr. Kulmani Mehar.
18695A0332 M.Vijaya Bhaskar
17691A03F4 T.Ravi Tej
17691A03H7
B.Santhosh Naik
Department of Mechanical Engineering
Madanapalle Institute of Technology & Science (UGC - AUTONOMOUS)
An ISO 9001:2008 Certified Institution, Accredited by NBA
May 2021 1
Introduction
• 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
• Problem and review on recent literatures Gear drive is one of the most important types of
mechanical transmission. Optimal design of gear drive is helpful to the conservation of
resources and the reduction of cost as well as its working performance is greatly improved. In
the past one decade, there are many relevant achievements on the optimal design of gear
drive.mathematical models are constructed to minimize the weight, the total volume and the
total center distance of gear reducers, respectively.some optimal design methods are
presented to reduce the vibration and the noise of the system of gear drive.
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 Case Hardened steel and carbon fiber 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 review
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 comparison 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
 Geometry/ Model/Set up

Isometric view of pinion and gear without holes Meshing of pinion and gear without holes
• Pinion and gear is designed in solid works
• Meshing is done in ANSYS
Geometry/ Model/set up

Isometric view of pinion and gear with circular holes Meshing of pinion and gear with Circular holes in all
in all the teeth the teeth
Geometry/ Model/set up

Isometric view of pinion and gear with circular holes Meshing of pinion and gear with Circular holes
in alternate teeth in alternate teeth
Input parameters
• Analysis with static load of 50 N applied on the model gear and pinion.
• Analysis with Torque load of 100 NM applied on the model gear and pinion.
• Diameter of small gear 53.6cm
• Diameter of big gear 90.1
• No of teeth on big gear 83
• No of teeth on small gear20
Analysis Results :
Static load on All the teeth for 40Ni 2 Cr1 Mo28 steel :
Results Total deformation Equivalent stress Equivalent strain
Minimum 0mm 1.0851 x10-8kgf/cm2 1.4842 x 10-7mm/mm
Maximum 11.045 mm 7.26 x10-2kgf/cm2 0.4256 mm/mm
Average 4.7566 mm 9.2487 x10-4kgf/cm2 4.6564 x10-3mm/mm

Static load on All the teeth for Carbon Fiber :

Results Total deformation Equivalent stress Equivalent strain
Minimum 0mm 8.9004x10-9kgf/cm2 5.2856x 10-14mm/mm
Maximum 9.1989 x10-6mm 6.2593x10-2kgf/cm2 3.5144 x 10-7mm/mm

Average 4.0088 x10-6 mm 8.8611x10-4kgf/cm2 4.0915 x10-9mm/mm

Static load on Alternate teeth for 40Ni 2 Cr1 Mo28 steel :
Results Total deformation Equivalent stress Equivalent strain
Minimum 0mm 3.4968 x10-8kgf/cm2 1.9127 x 10-7mm/mm
Maximum 12.66 mm 6.6398x10-2kgf/cm2 0.53114 mm/mm
Average 3.404 mm 8.6372 x10-4kgf/cm2 4.2674 x10-3mm/mm

Static load on Alternate teeth for Carbon Fiber :

Results Total deformation Equivalent stress Equivalent strain
Minimum 0mm 3.9206 x10-8kgf/cm2 2.0909 x 10-13mm/mm
Maximum 1.1354 x10-5 mm 6.8997 x10-2kgf/cm2 4.8635 x 10-7mm/mm

Average 2.8957 x10-6 mm 8.6868 x10-4kgf/cm2 3.9796 x10-9mm/mm

Static load on pinion and gear without holes for 40Ni 2 Cr1 Mo28 steel :
Results Total deformation Equivalent stress Equivalent strain
Minimum 0mm 6.3605 x10-9kgf/cm2 7.6238 x 10-8mm/mm
Maximum 10.677 mm 7.538 x10-2kgf/cm2 0.3578 mm/mm
Average 4.3637 mm 9.507 x10-4kgf/cm2 4.6671 x10-3mm/mm

Static load on pinion and gear without holes for Carbon

Fiber :
Results Total deformation Equivalent stress Equivalent strain
Minimum 0mm 9.2612 x10-9kgf/cm2 5.252 x 10-14mm/mm
Maximum 8.9407 x10-6mm 5.6563 x10-2kgf/cm2 2.5513 x 10-7mm/mm

Average 3.6615 x10-6 mm 9.1826 x10-4kgf/cm2 4.155 x10-9mm/mm

Torque load on pinion and gear without holes for 40Ni 2 Cr1 Mo28 steel
Results Total Deformation Equivalent stress Equivalent strain
Minimum 0mm 8.8408 x 10-10kgf/cm2 8.745 x 10-9 mm/mm
Maximum 0.7146mm 7.1696 x 10-3kgf/cm2 4.0283x 10-2 mm/mm
Average 0.35772mm 3.5556 x 10-5kgf/cm2 1.7366 x 10-4 mm/mm

Torque load on pinion and gear without holes for Carbon Fiber :
Results Total Deformation Equivalent stress Equivalent strain

Minimum 0mm 1.9495 x 10-10kgf/cm2 2.6818 x 10-15 mm/mm

Maximum 6.3589 x 10-7 mm 7.4524 x 10-3kgf/cm2 4.0091 x 10-8mm/mm

Average 3.1108 x 10-7 mm 3.5533 x 10-5kgf/cm2 1.6066 x 10-10 mm/mm

Torque load on pinion and gear with holes in alternate teeth for 40Ni 2 Cr1 Mo28 steel

Results Total Deformation Equivalent stress Equivalent strain

Minimum 0mm 5.2154 x 10-9kgf/cm2 3.5323 x 10-8 mm/mm
Maximum 0.70376 mm 6.6298 x 10-3kgf/cm2 4.3372 x 10-2 mm/mm
Average 0.28149mm 3.9571 x 10-5kgf/cm2 1.9532 x 10-4 mm/mm
Torque load on pinion and gear with holes in alternate teeth for Carbon Fiber :

Results Total Deformation Equivalent stress Equivalent strain

Minimum 0mm 1.506 x 10-9kgf/cm2 9.6561 x 10-15 mm/mm

Maximum 6.2514 x 10-7mm 6.921 x 10-3kgf/cm2 4.2952 x 10-8 mm/mm

Average 2.4394 x 10-7 mm 4.0003 x 10-5kgf/cm2 1.8295 x 10-10 mm/mm

Torque load on pinion and gear with holes in all the teeth for 40Ni 2 Cr1 Mo28 steel :

Results Total Deformation Equivalent stress Equivalent strain

Minimum 0mm 7.2109 x 10-10kgf/cm2 6.9511 x 10-9 mm/mm
Maximum 0.60698mm 2.3516 x 10-3kgf/cm2 1.6139 x 10-2 mm/mm
Average 0.35403mm 2.5893 x 10-5kgf/cm2 1.29 x 10-4 mm/mm
Torque load on pinion and gear with holes in all the teeth for Carbon Fiber :

Results Total Deformation Equivalent stress Equivalent strain

Minimum 0mm 3.2575 x 10-10kgf/cm2 2.6652 x 10-15 mm/mm

Maximum 5.4114 x 10-7mm 2.4433 x 10-3kgf/cm2 1.5819 x 10-8 mm/mm

Average 3.0881 x 10-7 mm 2.5634 x 10-5kgf/cm2 1.1848 x 10-10 mm/mm

Total deformation of pinion and gear without holes of 40Ni 2 Cr1 Mo28

steel and Carbon Fiber when static load is applied

Stress analysis of pinion and gear without holes of 40Ni 2 Cr1 Mo28
steel & Carbon Fiber when static load is applied
Strain analysis on pinion and gear without holes of 40Ni 2 Cr1 Mo28
steel and Carbon Fiber when static load is applied
Total deformation on pinion and gear without holes of 40Ni 2 Cr1 Mo28steel and
Carbon Fiber when Torque load is applied
Stress analysis of pinion and gear without holes of 40Ni 2 Cr1
Mo28steeland Carbon Fiber when torque load is applied
Strain analysis of pinion and gear without holes of 40Ni 2 Cr1 Mo28
steel and Carbon Fiber when torque load is applied
Total deformation of pinion and gear with holes in all teeth of
40Ni 2 Cr1 Mo28 steel and Carbon Fiber when static load is applied
Stress analysis of pinion and gear with holes in all teeth of
40Ni 2 Cr1 Mo28 steel and Carbon Fiber when static load is applied
Strain analysis of pinion and gear with holes in all teeth of
40Ni 2 Cr1 Mo28 steel and Carbon Fiber when static load is applied
Total deformation of pinion and gear with holes in alternate teeth of
40Ni 2 Cr1 Mo28 steel and Carbon Fiber when static load is applied
Stress analysis of pinion and gear with holes in alternate teeth of
40Ni 2 Cr1 Mo28 steel and Carbon Fiber when static load is applied
nalysis of pinion and gear with holes in alternate teeth of
40Ni 2 Cr1 Mo28 steel and Carbon Fiber when static load is applied
al deformation of pinion and gear with holes in all teeth of
40Ni 2 Cr1 Mo28 steel and Carbon Fiber when torque load is applied
Strain analysis of pinion and gear with holes in all teeth of
40Ni 2 Cr1 Mo28 steel and Carbon Fiber when torque load is applied
ress analysis of pinion and gear with holes in all teeth of
40Ni 2 Cr1 Mo28steel and Carbon Fiber when torque load is applied
 Total deformation of pinion and gear with holes in alternate teeth of
40Ni 2 Cr1 Mo28 steel and Carbon Fiber when torque load is applied
Strain analysis of pinion and gear with holes in alternate teeth of
40Ni 2 Cr1 Mo28 steel and Carbon Fiber when torque load is applied
Stress analysis of pinion and gear with holes in alternate teeth of
40Ni 2Cr1 Mo28 steel and Carbon Fiber when torque load is applied
Graphical Comparison :
Comparison of Torque loads (Equivalent Stress) : 40Ni 2 Cr1 Mo28 steel vs Carbon Fiber:
Comparison of Static loads (Equivalent Stress) : 40Ni 2 Cr1 Mo28 steel vs Carbon Fiber:
Comparison of Static loads (Total Deformation) : 40Ni 2 Cr1 Mo28 steel vs Carbon Fiber:
Comparison of Torque loads (Total Deformation) : 40Ni 2 Cr1 Mo28 steel vs Carbon Fiber:
RESULTS DISCUSSION AND CONCLUSION

• Design and modeling of a gear, pinion and the meshing, was successfully completed using solidworks
design tool and basic static analysis completed using ANSYS.
• We know that with the increase of stress, life of gear decreases. The maximum stress in a gear will be
near the root of the teeth.
• The results obtained from ANSYS reveals the Maximum Equivalent Stress values of meshed Gear and
Pinion without holes of 40Ni 2 Cr1 Mo28 steel and Carbon Fiber when static load is applied are 7.538
x10-2 kgf/cm2 and 5.6563 x10-2 kgf/cm2. Maximum Equivalent Stress values of meshed Gear and Pinion
with holes in the center of alternate teeth of 40Ni 2 Cr1 Mo28 steel and Carbon Fiber when static load
is applied are 6.6398 x10-2 kgf/cm2 and 6.8997 x10-2 kgf/cm2.Maximum Equivalent Stress values of
meshed Gear and Pinion with holes in the center of all the teeth of 40Ni 2 Cr1 Mo28 steel and Carbon
Fiber when static load is applied are 7.26 x10-2 kgf/cm2 and 6.2593 x10-2 kgf/cm2.
• The Maximum Equivalent Stress values of meshed Gear and Pinion without holes of 40Ni 2 Cr1
Mo28 steel and Carbon Fiber when torque load is applied are 7.1696 x10 -3 kgf/cm2 and 7.4524 x10-3
kgf/cm2. Maximum Equivalent Stress values of meshed Gear and Pinion with holes in the center of
alternate teeth of 40Ni 2 Cr1 Mo28 steel and Carbon Fiber when torque load is applied are 6.6298 x10 -
3 kgf/cm2 and 6.921 x10 -3 kgf/cm2.Maximum Equivalent Stress values of meshed Gear and Pinion with

holes in the center of all the teeth of 40Ni 2 Cr1 Mo28 steel and Carbon Fiber when torque load is
applied are 2.3516 x10 -3 kgf/cm2 and 2.4433 x10-3 kgf/cm2.
• Since the Gear drive is subjected to torque load, considering the maximum stress analysis report of
Gear and Pinion of 40Ni 2 Cr1 Mo28 steel with hole at center of the teeth in all the teeth gives the
lesser stress values when compared to the hole at center of the teeth in alternate teeth and Gear teeth
without holes. Similar pattern is followed in the Carbon Fiber also.
• Also when the Gear drive is subjected to torque load, considering the maximum Total deformation
analysis report of Gear and Pinion of 40Ni 2 Cr1 Mo28 steel with hole at center of the teeth in all the
teeth gives the lesser values when compared to the hole at center of the teeth in alternate teeth and
Gear teeth without holes. Similar pattern is followed in the Carbon Fiber also.
• Comparing the materials used, even carbon fiber can be used as an alternate material for case
hardened steel and it is also capable of withstanding the equivalent maximum stress without failure.
• The stress values obtained in pinion and wheel resembles the same pattern for the position of the
hole. Hole at the center of all teeth along the pitch circle diameter reduces the maximum stress as
compared to the hole at the center of alternate teeth.
• The holes introduced reduces the stress values and hence called as stress-relieving hole. It might
decrease the fatigue strength of gear, but it is also more possible to improve the fatigue strength due
to relieving the max stress. 
• With best result which was obtained in both pinion and wheel with hole at center of the all the teeth
on Pitch circle diameter. Reduction in stress is possible with circular hole as a stress relieving
feature. Stresses are very much sensitive to the location and size of stress relieving features. It may
be difficult to determine the correct location of a stress relieving feature.
References
1. Pinaknath Dewanji,”Design and analysis of spur gear” International Journal of Mechanical
Engineering and Technology (IJMET) Volume 7, Issue 5, September–October 2016 IAEME
Publication (2016)
2. Devender singh , “Structural analysis of spur gear using FEM” International Journal of
Mechanical Engineering and Technology (IJMET) Volume 7, Issue 6,November-December 2016
IAEME Publication (2016)
3. S.Mahendran, K.M.Eazhil , L.Senthil Kumar, “Design and Analysis of Composite Spur Gear
“International journal and Research of Scientific innovation(IJRSI) Volume1, Issue 6,
November 2015
4. Ram Krishna rathore & abhishek Tiwari, “Bending stress analysis & optimization of spur gear”
International Journal of Engineering Research & Technology (IJERT) volumr 3, Issue 5 , may
2014.
5. IGOR L.GLIKSON & ALEXANDER A.STUPAKOV “Modernization of Main Helicopter
Gearbox with Asymmetric Tooth Gears” ASME 2013 International Design Engineering
Technical Conferences & Computers and Information in Engineering Conference IDETC/CIE
2013IDETC/CIE(August 2013)
6. Vivek Singh, Sandeep Chauhan,“Finite Element Analysis Of A Spur Gear Tooth Using Solid