To achieve improved static gear drives and enhanced load carrying capacity and reliability, a complete studyabout gear drive design and analysis is carried out. The structural analysis is examined for spur gear drive. Geardrives transmit motion and power by tooth mesh mostly in the form of involute profiles, gear tooth mesh is acomplex process involving multi tooth engagement, multipoint contact and varying load conditions. The contactstresses were examined using 3-D FEM model. The gears are modeled by using AUTO- CAD and analyzed byANSYS 16.0. In the present work an attempt is proposed to find the structural analysis at the point of gear toothengagement under static loading conditions through finite element softwar

,Mr. Rajiv Arya, Mr. S. Vishwakarma1, Mr. S. Sharma

English

Smart Moves Journal IJOSTHE (International Journal Online of Sports Technology & Human Engineering)

IJOSTHE ISSN: 2349-0772 | Volume IV Issue VI December 2017  www.ijosthe.com     STRUCTURAL ANALYSIS OF SPUR GEAR USING FEM  S. Vishwakarma1, S. Sharma2 and Rajiv Arya3 Department of Mechanical Engineering,  Muzaffarpur Institute of Technology, Muzaffarpur.  ABSTRACT-  To achieve improved static gear drives and enhanced load carrying capacity and reliability, a complete study about gear drive design and analysis is carried out. The structural analysis is examined for spur gear drive. Gear drives transmit motion and power by tooth mesh mostly in the form of involute profiles, gear tooth mesh is a complex process involving multi tooth engagement, multipoint contact and varying load conditions. The contact stresses were examined using 3-D FEM model. The gears are modeled by using AUTO- CAD and analyzed by ANSYS 16.0. In the present work an attempt is proposed to find the structural analysis at the point of gear tooth engagement under static loading conditions through finite element software.  Key words: Spur gear, CAD, ANSYS, Static analysis, Total deformation, FEM.   1. INTRODUCTION  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.  Spur Gears: -The spur gear is simplest type of gear manufactured and is generally used for transmission of rotary motion between parallel shafts. The spur gear is the first choice option for gears except when high speeds, loads, and ratios direct towards other options. Other gear types may also be preferred to provide more silent low- vibration operation. A single spur gear is generally selected to have a ratio range of between 1:1 and 1:6 with a pitch line velocity up to 25 m/s. The spur gear has an operating efficiency of 98-99%. The pinion is made from a harder material than the wheel. A gear pair should be selected to have the highest number of teeth consistent with a suitable safety margin in strength and wear. The minimum numbers of teeth on a gear with a normal pressure angle of 20 degrees are 18 and 15.This is a cylindrical shaped gear in which the teeth are parallel to the axis. It has the largest applications and also it is the easiest to manufacture.  They are simple in construction, easy to manufacture and cost less. They have highest efficiency and excellent precision rating. They are used in high speed and high load application in all types of trains and a wide range of velocity ratios. Hence, they find wide applications right from clocks, household gadgets, motor cycles, automobiles, and railways to aircrafts. IJOSTHE ISSN: 2349-0772 | Volume IV Issue IV December 2017  www.ijosthe.com                    Figure 1: Spur gear  Mahendran, K.M.Eazhil, L.Senthil Kumar [1] carried out DESIGN AND ANALYSIS OF COMPOSITE SPUR GEAR. This project includes design of the spur gear to study the weight reduction and stress distribution for cast steel and composite materials. They designed the spur gear model using design software and studied the impact analysis and torque loading fore cast steel and composite materials. Finally, by comparing and analyzing the composite gear with existing cast steel gear they concluded that the stress induced, deformation and weight of the composite spur gear is less as compared to the cast steel spur gear.  Utkarsh.M.Desail, Prof.Dhaval.A.Patel [2] carried out MODELING AND STRESS ANALYSIS OF COMPOSITE MATERIAL FOR SPUR GEAR UNDER STATIC LOADING CONDITION. The objective of this project is to improve the performance of gear by using alternate materials.  Composite materials provide adequate strength with weight reduction and they are emerging as a better alternative for replacing metallic gears. In this work, a metallic gear of Alloy Steel is replaced by the composite gear of 30% Glass filled Poly-Ether-Ether-Ketone(PEEK) to increase the working life of the gears to improve overall performance of machine. Such composite materials provide much improved mechanical properties such as better strength to weight ratio, more hardness, and hence less chances of failure. In this project, the modeling of spur gear is carried out using SOLIDWORKS and bending stress analysis of spur gear is arrived out using ANSYS V14.  R. Yakut et al [3]. The purpose of the paper is to examine the load capacity of PC/ABS spur gears and investigation of gear damage. Further in this study usability of PC/ABS composite plastic material as spur gear was investigated and was defined that PC/ABS gears were tested by applying three different loading at two different numbers of revolutions on the FZG experiment set. The experiment result summarized that the usage of PC/ABS materials brings an advantage in many industrial area because such materials are durable against flame, air, ultraviolet lights and holding lower moister than PA66 GFR 30 materials.The another result of this study was that good operating conditions are comprised at low numbers of revolution and the tooth loads. Further the suitable environmental condition must be revolutions and the tooth load for gears. PC/ABS gear should be preferred at low tooth and unwanted high power transmission.  V. Siva Prasad et al [4]. This paper describes design and analysis of spur gear and it is proposed to substitute the metallic gears of sugarcane juice machine with polymer gears to reduce the weight and noise. A virtual model of spur gear was created in PRO-E, Model is imported in ANSYS 10.0 for analysis by applying normal load condition. The main purpose of this paper to analysis the different polymer gears namely nylon, polycarbonate and their viability checked with counterpart metallic gear like as cast iron. Concluding the study using the FEA methodology, it can be proved that the composite gears, if well designed and analyzed, will give the useful properties like as a low cost, noise, weight, vibration and perform its operation similar to the metallic gears. Based on the static analysis Nylon gears are suitable for the application of sugarcane juice machine under limited load condition in comparison with cast iron spur gears.  Vivek Karaveer et al [5]. This paper presents the stress analysis of mating teeth of the spur gear to find maximum contact stress in the gear tooth The results obtained from finite element analysis are compared with theoretical Hertz equation values. The spur gears are modeled and assembled in ANSYS DESIGN MODELER and stress analysis IJOSTHE ISSN: 2349-0772 | Volume IV Issue IV December 2017  www.ijosthe.com  of Spur gear tooth is done by the ANSYS 14.5 software. It was found that the results from both Hertz equation and Finite Element Analysis are comparable. From the deformation pattern of steel and grey cast iron, it could be concluded that difference  between  the  maximum  values  of steel and grey CI gear deformation is very less.       Table 1: Properties of Gray Cast Iron                        Material     Gray Cast Iron                        Young modulus     = 110 GPa                         Poisson’s ratio     = 0.28                        Ultimate Tensile Strength   = 430 MPa                       Ultimate Compressive Strength   = 820MPa                         Yield Tensile Strength     = 276 MPa                         Bulk modulus     = 83.3 GPa                      Table 2: Symbol and descriptions                       Symbol     Descriptions                   α    Pressure angle Outside       O.D    Diameter Pitch circle       P.C.D    diameter Module        m    Number of teeth        Z    Center Distance        C.D.                           Table 3: Specifications of spur gear                     Specifications    Pinion   Gear      α  20 0    20 0                   O.D  100mm    85mm                   P.C.D  90mm    75mm       m                         Z  5mm    5mm       C.D.  18   15          82.5mm    82.5mm                      2. STATIC ANALYSIS  Static analysis is concerned with determination of response of a gear to steady loads whose response remains unchanged with time. The response of the gear is expressed in terms of stress, strain, displacement. The tool used in the static analysis is Static structural.  The finite element analysis procedure of the spur gear was given below:  A three-dimensional model of the spur gear was created using the pro/engineer CAD software. The material properties were defined for gears.  The model was meshed using finite element software. IJOSTHE ISSN: 2349-0772 | Volume IV Issue IV December 2017  www.ijosthe.com  Boundary conditions for ANSYS Workbench as mentioned below. Fixed displacement constraint was applied on gear  A Revaluated joints is provided to each gears with Body-Ground connection. The revolution of gears is ready as 60 revolutions per minute  In order to arrest the displacement on x, y, z directions and rotations on x, y directions remote displacement constraint is applied on pinion surface.                      Figure 2: A three-dimensional model of the spur gear  Figure 3 shows the meshed finite element model of the spur gear which had been utilized for the analysis.                      Figure 3: Meshed model of spur gear  3. RESULTS AND DISCUSSIONS Static Analysis  The below figure shows contact stress on tooth meshing area made up of Gray Cast Iron with hardening and tempering. The maximum and minimum von-mises stress values found are 976.19 N/mm2 and 0.0034781 N/mm2. IJOSTHE ISSN: 2349-0772 | Volume IV Issue IV December 2017  www.ijosthe.com                        Figure 4.5: Total Deformation of Spur gears  The maximum and minimum total deformation values found are 3.253mm and 0.34907 mm.                        Figure 4.5: Von-Mises Stress of Spur gears  The maximum and minimum von-mises stress values found is 976.19 N/mm2 and 0.0034781 N/mm2.  4. CONCLUSION  This project work focuses three dimensional spur gear analyses under static conditions. The purpose of three-dimensional analysis is to predict the gear behavior on real operating conditions. In the static analysis, gear is fixed and rotational load is applied on pinion. In dynamic analysis of gear both gear and pinion are allowed to rotate in opposite direction on time basis. From analysis it is proved as per theory that once the gear meshes and stars to rotate they are subjected to maximum deformation.  The total deformation of Spur Gear has been observed 3.253 mm.  The Directional deformation of Spur Gear has been observed, its value is 3.27mm  The Equivalent stress (von-mises stress) of Spur Gear has been observed, its maximum value is 976.16 Mpa. IJOSTHE ISSN: 2349-0772 | Volume IV Issue IV December 2017  www.ijosthe.com  REFERENCE  [1] V. Siva Prasad, Syed   AltafHussain,   V.Pandurangadu, K.PalaniKumar. Modeling and  Analysis of  Spur  Gear  for Sugarcane Ju ice Machine under Static Load Condition by Using FEA. International Journal of Modern Engineering Research (2012), 2(4):2862 -2866.  [2] Mahebub Vohra, Prof. Kevin Vyas "Comparative Finite Element Analysis of Metallic and non Metallic spur gear", May -June 2014, IOSR Journal of Mechanical and Civil Engineering, 11(3):136 -145.   [3] Lin Tengjiao, Ou H., Li Runfang. 2007. A finite element method for 3D static and dynamic contact/impact analysis of gear drives, Computer Methods in Applied Mechanics and Engineering, 196(9 -12):1716-1728.   [4] Kahraman A.,  Kharazi A.  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STRUCTURAL ANALYSIS OF SPUR GEAR USING FEM

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STRUCTURAL ANALYSIS OF SPUR GEAR USING FEM

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Smart Moves Journal IJOSTHE (International Journal Online of Sports Technology & Human Engineering)