Abstract: In this paper, an (irregular) case relating to base circle, root circle, and pressure angle has been discussed and a computer programme has been developed to simulate and plot spur gear tooth profile, including involute and trochoid curves based on the formulation of rack cutter using different values of pressure angle and profile shift factor and it gave the values of all important geometric parameters. The results showed the flexibility of this approach and versatility of the programme to draw many different cases of spur gear teeth of any module, pressure angle, profile shift factor, number of teeth and rack cutter tip radius. The procedure developed can be extended to produce finite element models of heretofore intractable geometrical forms, to exploring fabrication of nonstandard tooth forms also. Finite elements model of these irregular cases have been built using above programme, and modal analysis has been done using ANSYS software, and natural frequencies of these selected cases have been obtained and discussed.
Abstract: The estimation of gear tooth stiffness is important for finding the load distribution between the gear teeth when two consecutive sets of teeth are in contact. Based on dynamic model a C-program has been developed to compute mesh stiffness. By using this program position dependent mesh stiffness of spur gear tooth for various profile shifts have been computed for a fixed center distance and altering tooth-sum gearing (100 by ± 4%). It is found that the C-program using dynamic model is one of the rapid soft computing technique which helps in design of gears. The mesh tooth stiffness along the path of contact is studied for both 20° and 25° pressure angle gears at various profile shifts. Better tooth stiffness is noticed in case of negative alteration tooth-sum gears compared to standard and positive alteration tooth-sum gears. Also, in case of negative alteration tooth-sum gearing better mesh stiffness is noticed in 20° pressure angle when compared to 25°.
Abstract: A new approach has been developed to estimate the
load share and distribution of worm gear drives, and to calculate the
instantaneous tooth meshing stiffness. In the approach, the worm gear
drive was modelled as a series of spur gear slices, and each slice was
analyzed separately using the well-established formulae of spur gear
loading and stresses. By combining the results obtained for all slices,
the entire envolute worm gear set loading and stressing was obtained. The geometric modelling method presented allows tooth elastic
deformation and tooth root stresses of worm gear drives under
different load conditions to be investigated. Based on the slicing
method introduced in this study, the instantaneous meshing stiffness
and load share are obtained. In comparison with existing methods,
this approach has both good analysis accuracy and less computing
time.
Abstract: This paper investigates the effects of lubrication on
the quantity of heat emission of two spur gear. System with and
without lubrication effected on the quantity of heat induced on the
gear box (oil - bearings – gears). Both of lubrication and speed of
motor are affected on the performance of gears. Research investigated
the lubrication on the system with and without loading as well as the
wear of gears and bearing's conditions. Gear box investigated
includes the motor, pump, two spur gears, two shafts; speed change
used pulleys and belts. Load used equal one weight ones of gear.
Lubrication mechanism used jet system (upper and lower jet). Gear
box we used system of jet lubrication is perpendicular direction of
the contact line between two teeth. Results appeared in this work that
the lubrication is the vital parameter which is affected on the
performance and durability of gears and bearings. In macroscopic
observation, we noted that damage of bearings happened during the
absence of lubrication as well as abrasive of wear of teeth. Higher
speed of motor without lubrication increased the noise, but in the
presence of lubrication was decreased.
Abstract: Contact stress analysis between two spur gear
teeth was considered in different contact positions,
representing a pair of mating gears during rotation. A
programme has been developed to plot a pair of teeth in contact. This programme was run for each 3° of pinion
rotation from the first location of contact to the last location of
contact to produce 10 cases. Each case was represented a
sequence position of contact between these two teeth. The
programme gives graphic results for the profiles of these teeth
in each position and location of contact during rotation. Finite
element models were made for these cases and stress analysis
was done. The results were presented and finite element
analysis results were compared with theoretical calculations,
wherever available.
Abstract: New advancement of technology and never satisfying demands of the civilization are putting huge pressure on the natural fuel resources and these resources are at a constant threat to its sustainability. To get the best out of the automobile, the optimum balance between performance and fuel economy is important. In the present state of art, either of the above two aspects are taken into mind while designing and development process which puts the other in the loss as increase in fuel economy leads to decrement in performance and vice-versa. In-depth observation of the vehicle dynamics apparently shows that large amount of energy is lost during braking and likewise large amount of fuel is consumed to reclaim the initial state, this leads to lower fuel efficiency to gain the same performance. Current use of Kinetic Energy Recovery System is only limited to sports vehicles only because of the higher cost of this system. They are also temporary in nature as power can be squeezed only during a small time duration and use of superior parts leads to high cost, which results on concentration on performance only and neglecting the fuel economy. In this paper Kinetic Energy Recovery System for storing the power and then using the same while accelerating has been discussed. The major storing element in this system is a Flat Spiral Spring that will store energy by compression and torsion.
The use of spring ensure the permanent storage of energy until used by the driver unlike present mechanical regeneration system in which the energy stored decreases with time and is eventually lost. A combination of internal gears and spur gears will be used in order to make the energy release uniform which will lead to safe usage. The system can be used to improve the fuel efficiency by assisting in overcoming the vehicle’s inertia after braking or to provide instant acceleration whenever required by the driver. The performance characteristics of the system including response time, mechanical efficiency and overall increase in efficiency are demonstrated. This technology makes the KERS (Kinetic Energy Recovery System) more flexible and economical allowing specific application while at the same time increasing the time frame and ease of usage.
Abstract: This paper presents the study of hardness profile of spur gear heated by induction heating process in function of the machine parameters, such as the power (kW), the heating time (s) and the generator frequency (kHz). The global work is realized by 3D finite-element simulation applied to the process by coupling and resolving the electromagnetic field and the heat transfer problems, and it was performed in three distinguished steps. First, a Comsol 3D model was built using an adequate formulation and taking into account the material properties and the machine parameters. Second, the convergence study was conducted to optimize the mesh. Then, the surface temperatures and the case depths were deeply analyzed in function of the initial current density and the heating time in medium frequency (MF) and high frequency (HF) heating modes and the edge effect were studied. Finally, the simulations results are validated using experimental tests.
Abstract: In this study, the precision heading process of
spur gears has been investigated by means of numerical
analysis. The effect of some parameters such as teeth number
and module on the forming force and material flow were
presented. The simulation works were performed rigid-plastic
finite element method using DEFORM 3D software. In order
to validate the estimated numerical results, they were
compared with those obtained experimentally during heading
of spur gear using lead as a model material. Results showed
that the optimum number of gear teeth is between 10 to 20,
that is because of being the specific pressure in its minimum
value.
Abstract: Natural frequencies and dynamic response of a spur
gear sector are investigated using a two dimensional finite element
model that offers significant advantages for dynamic gear analyses.
The gear teeth are analyzed for different operating speeds. A primary
feature of this modeling is determination of mesh forces using a
detailed contact analysis for each time step as the gears roll through
the mesh. ANSYS software has been used on the proposed model to
find the natural frequencies by Block Lanczos technique and
displacements and dynamic stresses by transient mode super position
method. The effect of rotational speed of the gear on the dynamic
response of gear tooth has been studied and design limits have been
discussed.
Abstract: Natural frequencies and dynamic response of a spur
gear sector are investigated using a two dimensional finite element
model that offers significant advantages for dynamic gear analyses.
The gear teeth are analyzed for different operating speeds. A primary
feature of this modeling is determination of mesh forces using a
detailed contact analysis for each time step as the gears roll through
the mesh. Transient mode super position method has been used to
find horizontal and vertical components of displacement and
dynamic stress. The finite element analysis software ANSYS has
been used on the proposed model to find the natural frequencies by
Block Lanczos technique and displacements and dynamic stresses by
transient mode super position method. A comparison of theoretical
(natural frequency and static stress) results with the finite element
analysis results has also been done. The effect of rotational speed of
the gears on the dynamic response of gear tooth has been studied and
design limits have been discussed.
Abstract: The exploration of this paper will focus on the Cshaped
transition curve. This curve is designed by using the concept
of circle to circle where one circle lies inside other. The degree of
smoothness employed is curvature continuity. The function used in
designing the C-curve is Bézier-like cubic function. This function has
a low degree, flexible for the interactive design of curves and
surfaces and has a shape parameter. The shape parameter is used to
control the C-shape curve. Once the C-shaped curve design is
completed, this curve will be applied to design spur gear tooth. After
the tooth design procedure is finished, the design will be analyzed by
using Finite Element Analysis (FEA). This analysis is used to find
out the applicability of the tooth design and the gear material that
chosen. In this research, Cast Iron 4.5 % Carbon, ASTM A-48 is
selected as a gear material.
Abstract: This paper presents the study of induced currents and
temperature distribution in gear heated by induction process using 2D
finite element (FE) model. The model is developed by coupling
Maxwell and heat transfer equations into a multi-physics model. The
obtained results allow comparing the medium frequency (MF) and
high frequency (HF) cases and the effect of machine parameters on
the evolution of induced currents and temperature during heating.
The sensitivity study of the temperature profile is conducted and the
case hardness is predicted using the final temperature profile. These
results are validated using tests and give a good understanding of
phenomena during heating process.
Abstract: In the present paper, we use generalized B-Spline curve in trigonometric form on circular domain, to capture the transcendental nature of circle involute curve and uncertainty characteristic of design. The required involute curve get generated within the given tolerance limit and is useful in gear design.
Abstract: This work presents a numerical model developed to
simulate the dynamics and vibrations of a multistage tractor gearbox.
The effect of time varying mesh stiffness, time varying frictional
torque on the gear teeth, lateral and torsional flexibility of the shafts
and flexibility of the bearings were included in the model. The model
was developed by using the Lagrangian method, and it was applied to
study the effect of three design variables on the vibration and stress
levels on the gears. The first design variable, module, had little effect
on the vibration levels but a higher module resulted to higher bending
stress levels. The second design variable, pressure angle, had little
effect on the vibration levels, but had a strong effect on the stress
levels on the pinion of a high reduction ratio gear pair. A pressure
angle of 25o resulted to lower stress levels for a pinion with 14 teeth
than a pressure angle of 20o. The third design variable, contact ratio,
had a very strong effect on both the vibration levels and bending
stress levels. Increasing the contact ratio to 2.0 reduced both the
vibration levels and bending stress levels significantly. For the gear
train design used in this study, a module of 2.5 and contact ratio of
2.0 for the various meshes was found to yield the best combination
of low vibration levels and low bending stresses. The model can
therefore be used as a tool for obtaining the optimum gear design
parameters for a given multistage spur gear train.