This document describes a computer program developed to calculate bending and pitting stresses of gears using the AGMA methodology. The program was created using Microsoft Excel and MATLAB to extract equations from AGMA graphs, allowing stresses to be determined efficiently and quickly for any spur or helical gear geometry. Testing showed the program can accurately calculate stresses and safety factors. The document provides background on AGMA standards, gear types, failure modes, and stresses considered in gear design.
IRJET - Surface Wear Analysis of Spur GearIRJET Journal
This document analyzes surface wear on spur gears made of cast iron operating at the theoretical wear load capacity. A 3D model of a gear and pinion assembly was created in CATIA. Transient structural analysis was performed in ANSYS to analyze surface wear using Archard's wear equation. The analysis found the highest wear volume occurs near the tooth flank where sliding speed and contact pressure are also highest. Surface wear at the tooth flank increases bending stress and can create stress concentrations, leading to earlier failure. The document concludes surface wear analysis is important to understand gear durability operating at the theoretical wear load capacity.
Design and Development of All-Terrain Vehicle : Volume 1IRJET Journal
This document describes the design and development of an all-terrain vehicle (ATV) chassis for competition. The authors designed the chassis using computer-aided design and analyzed it using finite element analysis software. They selected AISI 4130 steel for the material and a 25.4mm outer diameter and 3mm wall thickness tube for the cross-section, as it provided better strength and stiffness than alternatives. Under various impact simulations, the maximum stresses on the chassis were below the material yield strength, indicating a safety factor above 1 and that the design would withstand impacts without harming the driver.
An ATV roll cage is a specially designed protective frame around the driver that protects the driver in each & every condition. During the designing of roll cage take few objectives like diver safety, easy of manufacturing, light weight, ergonomics. This paper outline dynamic analysis of roll cage of ATV by doing per & post processing in ANSYS 18.2 & CAD modelling done in solid works 2018 to obtain optimum FOS (factor of safety) in worst condition under a set of particular rules given by Society of Automotive Engineers (SAE) Which ensure that the roll cage of ATV will be safe in all conditions.
Design and Development of Spur Gear by using Three Dimensional Printingijtsrd
Gears are power transmission devices in between input and output of machines, these power transmitting elements are very compact, and they transfer power with minimum loss. Due to the nature of their different speed ratios they are used for different applications like high speed marine engines, automobiles etc. Different materials are used for preparation or fabrication of gears like metals steel or brass , plastics nylon or polycarbonate . In this project spur gear is designed by CAD software and fabricated by using 3D printer, for 3D printing materials require like plastics or ceramics but for this project plastic material is used that is polylactic acid PLA . By using 3D printer spur gear is produced within a small period with better dimensional accuracy than conventional method like milling etc. P. Naresh | Aman Raj | J. Tarun | Ejazur Rahman | G. Bharat ""Design and Development of Spur Gear by using Three Dimensional Printing"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23236.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/23236/design-and-development-of-spur-gear-by-using-three-dimensional-printing/p-naresh
Design and Analysis of Go Kart Chassis for Front, Side and Rear Impactijtsrd
This paper deals with Go kart chassis building with the help of modelling software CATIA V15 and analysis of the same for front, side and rear impact. The cassis has been designed for light weight profile and engine mounting of capacity 135cc. The go kart vehicle is meant for participation in various Go kart event organized all over the India. The preliminary test for these events is checking of 3 D model of the chassis frame and analysis of the same chassis frame under front, side and rear impact. During collision the chassis is under impact loading conditions so it has to be thoroughly analyzed for impact loads. The studies found below shades some light on how the chassis behaves under impact loading conditions. Chassis is made up of a tubular cross section pipe, fabricated assembly of EN8 grade and a few other grades. In this kart, we have used EN8 class tube with 1 inch diameter and 1.5 mm wall thickness. The results obtained for permissible stresses, Factor of safety and deformation are found to be well within range. This makes the chassis suitable for Go kart events. The main criteria that has been focused here is maximum deformation and stress. The stresses should be well within Von mises stress range and so as the Factor of safety. After analysis, both are found to be well within range. Chetan Mahatme | Pratik Lande | Surendra Nagpure | Abhishek Pawar | Nikhil Kharabe ""Design and Analysis of Go-Kart Chassis for Front, Side and Rear Impact"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd22973.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/22973/design-and-analysis-of-go-kart-chassis-for-front-side-and-rear-impact/chetan-mahatme
IRJET- Design and Analysis of Concrete Diagrid Building and its Comparison wi...IRJET Journal
This document compares the structural behavior of a 10-storey concrete diagrid building to a conventional concrete building through modeling and analysis in STADD PRO software. Key findings include:
1) The diagrid structure experiences 33% less steel reinforcement compared to the conventional structure.
2) Shear forces and bending moments in beams and columns are generally lower in the diagrid building.
3) Storey drift is approximately half in the diagrid building compared to the conventional building.
4) The total volume of concrete used is 22.5% less in the diagrid building, showing it to be more economical.
IRJET - Finite Element Analysis of Shock AbsorberIRJET Journal
The document discusses the finite element analysis of a shock absorber. It begins with an introduction to shock absorbers and their purpose in vehicle suspension systems. It then describes the design calculations and modeling done for the helical springs and piston rod of the shock absorber. This includes calculating spring parameters like wire diameter and pitch based on applied forces. It also evaluates the piston rod design for safety against tensile failure. Next, the document discusses rigid body dynamics and mass property calculations done in the modeling. Finally, it presents the results of the structural analysis in ANSYS including stress, strain, deformation and kinematic analyses to evaluate the shock absorber design.
Design and Modeling of Pull Rod and Push Rod Suspension Systemijtsrd
This document discusses the design and modeling of pull rod and push rod suspension systems. It begins with an introduction to push rod and pull rod suspensions. It then describes the design of the suspension components using Lotus Shark software, including modeling the spring, damper, rocker arm, and push rods in SolidWorks. An assembly of the push rod suspension system is also designed. Calculations for the spring design are shown. The conclusion discusses the objectives of designing and modeling the suspension system and combining theoretical and practical knowledge.
IRJET - Surface Wear Analysis of Spur GearIRJET Journal
This document analyzes surface wear on spur gears made of cast iron operating at the theoretical wear load capacity. A 3D model of a gear and pinion assembly was created in CATIA. Transient structural analysis was performed in ANSYS to analyze surface wear using Archard's wear equation. The analysis found the highest wear volume occurs near the tooth flank where sliding speed and contact pressure are also highest. Surface wear at the tooth flank increases bending stress and can create stress concentrations, leading to earlier failure. The document concludes surface wear analysis is important to understand gear durability operating at the theoretical wear load capacity.
Design and Development of All-Terrain Vehicle : Volume 1IRJET Journal
This document describes the design and development of an all-terrain vehicle (ATV) chassis for competition. The authors designed the chassis using computer-aided design and analyzed it using finite element analysis software. They selected AISI 4130 steel for the material and a 25.4mm outer diameter and 3mm wall thickness tube for the cross-section, as it provided better strength and stiffness than alternatives. Under various impact simulations, the maximum stresses on the chassis were below the material yield strength, indicating a safety factor above 1 and that the design would withstand impacts without harming the driver.
An ATV roll cage is a specially designed protective frame around the driver that protects the driver in each & every condition. During the designing of roll cage take few objectives like diver safety, easy of manufacturing, light weight, ergonomics. This paper outline dynamic analysis of roll cage of ATV by doing per & post processing in ANSYS 18.2 & CAD modelling done in solid works 2018 to obtain optimum FOS (factor of safety) in worst condition under a set of particular rules given by Society of Automotive Engineers (SAE) Which ensure that the roll cage of ATV will be safe in all conditions.
Design and Development of Spur Gear by using Three Dimensional Printingijtsrd
Gears are power transmission devices in between input and output of machines, these power transmitting elements are very compact, and they transfer power with minimum loss. Due to the nature of their different speed ratios they are used for different applications like high speed marine engines, automobiles etc. Different materials are used for preparation or fabrication of gears like metals steel or brass , plastics nylon or polycarbonate . In this project spur gear is designed by CAD software and fabricated by using 3D printer, for 3D printing materials require like plastics or ceramics but for this project plastic material is used that is polylactic acid PLA . By using 3D printer spur gear is produced within a small period with better dimensional accuracy than conventional method like milling etc. P. Naresh | Aman Raj | J. Tarun | Ejazur Rahman | G. Bharat ""Design and Development of Spur Gear by using Three Dimensional Printing"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23236.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/23236/design-and-development-of-spur-gear-by-using-three-dimensional-printing/p-naresh
Design and Analysis of Go Kart Chassis for Front, Side and Rear Impactijtsrd
This paper deals with Go kart chassis building with the help of modelling software CATIA V15 and analysis of the same for front, side and rear impact. The cassis has been designed for light weight profile and engine mounting of capacity 135cc. The go kart vehicle is meant for participation in various Go kart event organized all over the India. The preliminary test for these events is checking of 3 D model of the chassis frame and analysis of the same chassis frame under front, side and rear impact. During collision the chassis is under impact loading conditions so it has to be thoroughly analyzed for impact loads. The studies found below shades some light on how the chassis behaves under impact loading conditions. Chassis is made up of a tubular cross section pipe, fabricated assembly of EN8 grade and a few other grades. In this kart, we have used EN8 class tube with 1 inch diameter and 1.5 mm wall thickness. The results obtained for permissible stresses, Factor of safety and deformation are found to be well within range. This makes the chassis suitable for Go kart events. The main criteria that has been focused here is maximum deformation and stress. The stresses should be well within Von mises stress range and so as the Factor of safety. After analysis, both are found to be well within range. Chetan Mahatme | Pratik Lande | Surendra Nagpure | Abhishek Pawar | Nikhil Kharabe ""Design and Analysis of Go-Kart Chassis for Front, Side and Rear Impact"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd22973.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/22973/design-and-analysis-of-go-kart-chassis-for-front-side-and-rear-impact/chetan-mahatme
IRJET- Design and Analysis of Concrete Diagrid Building and its Comparison wi...IRJET Journal
This document compares the structural behavior of a 10-storey concrete diagrid building to a conventional concrete building through modeling and analysis in STADD PRO software. Key findings include:
1) The diagrid structure experiences 33% less steel reinforcement compared to the conventional structure.
2) Shear forces and bending moments in beams and columns are generally lower in the diagrid building.
3) Storey drift is approximately half in the diagrid building compared to the conventional building.
4) The total volume of concrete used is 22.5% less in the diagrid building, showing it to be more economical.
IRJET - Finite Element Analysis of Shock AbsorberIRJET Journal
The document discusses the finite element analysis of a shock absorber. It begins with an introduction to shock absorbers and their purpose in vehicle suspension systems. It then describes the design calculations and modeling done for the helical springs and piston rod of the shock absorber. This includes calculating spring parameters like wire diameter and pitch based on applied forces. It also evaluates the piston rod design for safety against tensile failure. Next, the document discusses rigid body dynamics and mass property calculations done in the modeling. Finally, it presents the results of the structural analysis in ANSYS including stress, strain, deformation and kinematic analyses to evaluate the shock absorber design.
Design and Modeling of Pull Rod and Push Rod Suspension Systemijtsrd
This document discusses the design and modeling of pull rod and push rod suspension systems. It begins with an introduction to push rod and pull rod suspensions. It then describes the design of the suspension components using Lotus Shark software, including modeling the spring, damper, rocker arm, and push rods in SolidWorks. An assembly of the push rod suspension system is also designed. Calculations for the spring design are shown. The conclusion discusses the objectives of designing and modeling the suspension system and combining theoretical and practical knowledge.
IRJET - Design and Analysis of BAJA RollcageIRJET Journal
This document describes the design and finite element analysis of a roll cage for an all-terrain vehicle (ATV). The roll cage is designed to withstand forces from various impact directions. AISI 4130 steel is selected for its strength, durability, and weldability. The roll cage geometry is modeled in CAD software and analyzed in ANSYS for front, rear, side impacts and rollover. Front impact analysis at 7G deceleration showed a maximum von Mises stress of 623 MPa and a safety factor of 1.04, indicating the design is safe. Similar analyses were performed for rear and side impacts.
IRJET- Fatigue and Static Thermal Analysis of Brake Disc for SAE based CarsIRJET Journal
This document summarizes a study that performed fatigue and thermal analysis on a brake disc design for SAE-based cars. The authors used CATIA V5 to model the brake disc and ANSYS Workbench to perform coupled thermal-structural analysis. The analysis evaluated fatigue life, stress concentration, deformation, and thermal gradients under static and thermal loading conditions. The results showed maximum heat flux and temperature at the disc-pad contact region. High stresses occurred at hole regions due to stress concentration. Crack initiation was found to begin at the junction of holes where the lowest cross-sectional area results in highest stresses. The minimum fatigue life cycle was 8722.2 and maximum was 1x109 cycles.
IRJET-Analysis of Load Factors and Modes of Failure on Spur GearIRJET Journal
The document analyzes the load factors and modes of failure in spur gears. A finite element analysis is conducted to determine the load distribution factor in AGMA formulas for spur gears with different shaft misalignments. The 3D gear model is imported into ANSYS to calculate maximum bending and contact stresses using FEA. The results are then compared to analytical calculations to estimate the load distribution factor. Key factors influencing bending stress on gear teeth are also considered, including load distribution, stress concentration, and external factors.
Optimization and Comparison of Mono Leaf Spring using Different MaterialsIRJET Journal
The document presents a comparative study of mono leaf springs made from different materials, including steel, E-glass, Kevlar, and carbon fiber. Solidworks software was used to create solid models of the leaf springs and perform finite element analysis. The analysis found that Kevlar had the highest stress level but lowest displacement, while E-glass and carbon fiber had higher displacement but lower stress than steel. E-glass, Kevlar, and carbon fiber also exhibited lower strain and natural frequency than steel. However, the alternative materials provided significant weight reductions compared to steel, ranging from 74-82%. Overall, the study aimed to determine the most suitable material for mono leaf springs by comparing their mechanical behaviors under the same loading conditions
IRJET- Effect of Stiffened Element in Structural Behaviour of Steel Built...IRJET Journal
This document presents the results of an experimental study on the effect of different stiffening patterns on the structural behavior of steel built-up beams. Three beam models were tested: an unstiffened beam, a beam with longitudinal stiffeners, and a beam with an N-truss pattern stiffener. Testing results showed that the beam with the N-truss stiffener had the highest load carrying capacity at 42.2% more than the unstiffened beam and 23.04% more than the longitudinally stiffened beam. Deflections were also lowest for the N-truss beam. While more costly, the N-truss pattern provides significantly higher strength, making it preferable for applications requiring high load capacity.
STRESS ANALYSIS OF SPUR GEAR BY USING ANSYS WORKBENCHSumit Nagar
The document discusses analyzing the stress on a spur gear using ANSYS Workbench. It begins by providing background on different types of gears and power transmission systems. It then describes spur gears in particular, including their structure, functions, advantages, disadvantages, and applications. The document outlines the objectives of performing finite element analysis on a spur gear model to minimize stresses at critical locations, validate results with experimental data, and compare to theoretical analyses. The goal is to optimize the gear shape to reduce stresses.
Fatigue or Durability Analysis of Steering Knuckleijsrd.com
This document discusses fatigue or durability analysis of steering knuckles. It explains that structural components like steering knuckles need to withstand constant fluctuating loads over time. Fatigue analysis evaluates failure based on repeated loading rather than just material strength. Steering knuckles experience multiaxial loads from multiple directions from components like the strut mount, lower ball joint, and steering rod. Accurately analyzing fatigue damage requires identifying these multiaxial stresses. The document aims to analyze the random loads acting on a vehicle's steering knuckle under unstable road conditions.
Design of Flat belt, V belt and chain drivesDr. L K Bhagi
Geometrical relationships, Analysis of belt tensions, Condition for maximum power transmission, Characteristics of belt drives, Selection of flat belt, V- belt, Selection of V belt, Roller chains, Geometrical relationship, Polygonal effect, Power rating of roller chains, Design of chain drive, Introduction to belt drives and belt construction, Introduction to chain drives
IRJET- Experimental Stress Analysis of Worm Wheel used in Crate Washer GearboxIRJET Journal
This document describes an experimental stress analysis of a worm wheel used in a gearbox for a crate washer. The gearbox was experiencing failures of the worm wheel teeth due to excessive bending stresses. Both theoretical and experimental analyses were conducted. The theoretical analysis used Lewis' equation to calculate bending stresses. The experimental analysis used photo stress methods to directly measure stresses by applying loads that simulated actual operating conditions and observing colored fringe patterns with a polariscope. This allowed quantification of stresses at points of high stress. The analyses found the worm wheel's material and geometry were improperly selected for the application, leading to failures. The worm wheel was then redesigned with new material and geometry suitable for the required working conditions.
IRJET- A Critical Review on Bellow Part Removal FixtureIRJET Journal
This document provides a review of bellow removal fixtures. It begins with an abstract that describes bellows as flexible elements in expansion joints that absorb dimensional changes from forces and thermal expansion. It also describes fixtures as work holding devices that impact manufacturing quality, productivity and cost.
The document then reviews the design of bellow removal fixtures. It discusses key parameters like the fixture frame needing to be rigid to minimize deflection, fast clamping, and locating the workpiece with at least three fixed support points. It also reviews the "3-2-1" locating principle for prismatic parts. Finally, it concludes that fixtures are used for locating and holding workpieces, and that they are fixed to machines to aid mass production and reduce operator
IRJET-Split Casing Open Differential without Cross Pin and it’s Comparison wi...IRJET Journal
This document summarizes the design optimization of work roll chocks and backup roll chocks in a cold rolling mill. The current chocks were failing prematurely, resulting in production stoppages and costs. A 3D model of the chocks was created and analyzed using ANSYS software to determine stress distributions and critical areas under load. The design was iteratively optimized to reduce weight and material costs while maintaining structural integrity. The optimized design was found to reduce chock weight by over 10% and save $9,154.50 per chock based on material and production costs. Modal analysis confirmed the natural frequencies of the optimized design would not cause resonance issues. This new optimized chock design was concluded to provide improved life and cost
IRJET- Design and Durability Analysis of Ladder Chassis FrameIRJET Journal
This document summarizes a study that analyzed the design and durability of a ladder chassis frame for heavy-duty vehicles. The researchers designed the chassis frame model using PTC Creo software and analyzed it using Hypermesh FEA software. Their analysis subjected the frame to static loading conditions representing braking, cornering, and going over bumps. Initial results found the design passed normal loading but failed under high bump loading. The researchers then iteratively modified the design, focusing on reinforcing brackets, to improve strength and pass all loading conditions with safety factors above 1.
IRJET-Finite Element Analysis of Seat Belt Frame AssemblyIRJET Journal
This document presents a finite element analysis of a seat belt frame assembly. It aims to analyze deformation and von misses stress in the latch plate under different loads and thicknesses. Five case studies are conducted varying the thickness from 8mm to 4mm and loads from 63.5N to 350N. The results show that as thickness decreases, von misses stress increases. Failure occurs at 7mm thickness and 350N load. The latch plate is safe up to 250N for all thicknesses. An 8mm thick plate can withstand loads up to 350N. Deformations are negligible for all loads and thicknesses. Therefore, the optimal thickness for withstanding all loads is 8mm.
IRJET- Effect of Change of Parameters on Bending Stress in GearIRJET Journal
This document summarizes a study on the effect of changing parameters on bending stress in spur gears. The study models and simulates spur gear sets using CATIA and ANSYS Workbench software. It analyzes bending stress by varying the face width, number of teeth, and root fillet radius of the gear based on AGMA standards and Lewis equations. The results show that increasing the face width, number of teeth, and root fillet radius decreases the bending stress at the gear tooth interface and fillet region. The FEA results closely match the calculated stresses from standards. Increasing the parameters helps reduce bending stresses and strengthen the gear tooth.
This document describes the design, CAD modeling, and fabrication of an automatic hammering machine. The authors first discuss the objectives of the project, which are to determine impact velocity and torque force of the hammer, calculate the time required for operations, model the project in CATIA V5 software, enable automation with minimal manual effort, and achieve low costs. They then describe the components of the machine, including a DC motor, hammer, disc, drive shaft, and slider crank mechanism to convert rotary to linear motion. Analytical calculations are shown for torque, impact velocity, and shear stress. Finally, the document discusses CAD modeling of the system in CATIA and provides diagrams of the prototype model.
Stress analysis on steering knuckle of the automobile steering systemeSAT Publishing House
The document summarizes stress analysis performed on an automobile steering knuckle. It first describes the modeling of the steering knuckle using CAD software and applying loads equivalent to real-world conditions. A finite element analysis is then carried out to determine stress distributions and areas of high stress. The results show maximum stress concentrations that need to be considered in the steering knuckle design to avoid frequent failures and improve reliability.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Structural and Modal Analysis of Crane Hook with Different Materials using FeaIRJET Journal
This study analyzed the structural and modal behavior of a crane hook made from different materials using finite element analysis. A solid model of a crane hook with trapezoidal cross-section was created in CATIA and analyzed in ANSYS. Static structural analysis found that an aluminum alloy hook experienced lower stresses than a structural steel hook under the same load. Fatigue analysis determined the aluminum alloy hook could withstand more fatigue cycles before failure. Modal analysis revealed the structural steel hook had lower total deformation at the first natural frequency, indicating it is preferred for withstanding vibrations. In conclusion, the study found aluminum alloy suitable for withstanding loads but structural steel better for vibrations.
IRJET- Wind Analysis for RC Building using Belt TrussIRJET Journal
This document describes a study analyzing the use of belt trusses in reinforced concrete buildings to resist wind loads. The researchers created 3D models of a proposed building in ETABS with and without belt trusses placed at different intervals. They analyzed story drift, displacement, stiffness and base shear for each model under various wind load combinations specified in Indian codes. Results showed that placing belt trusses every 4 or 5 stories significantly reduced maximum story displacement and drift compared to the model without belt trusses. The optimal placement of belt trusses was found to be every 4 stories based on these performance indicators.
Modeling, simulation and optimization analysis of steering knuckle component ...eSAT Publishing House
This document summarizes a study that modeled, simulated, and optimized the design of a steering knuckle component for a race car. Five initial CAD models of the steering knuckle were created and analyzed using finite element analysis to determine stresses, displacements, and weights. The best design was then optimized using shape optimization software to reduce weight while maintaining strength. The optimized design achieved a 45.8% reduction in mass while still meeting strength requirements.
EPFO launched the Employees Enrolment Campaign, 2017, to encourage firms to enroll their employers to voluntarily come forward and declare details of all such employees who were entitled for membership between April 1, 2009 and December 31, 2016 under EPF & MP Act 1952, but could not be enrolled by them knowingly or due to lack of awareness of the Law.
Under the scheme, the employee's share of contribution, if declared by the employer as not deducted, shall stand waived, the Employees' Provident Fund Organization (EPFO) said in statement, to enroll the eligible workers who were left out, in bringing them under its social security umbrella.
Limestone PizzaStrategic Message PlannerMacaela Jones
Limestone Pizza aims to build brand awareness and increase sales by 10% by the end of May 2016. The campaign seeks to change Limestone's image from just a pizza place to a multi-faceted eatery that cares about the local community. Limestone opened in 2014 and produces fresh, locally-sourced dishes from scratch using sustainable practices. The target audience is eco-friendly men and women aged 21-45 who value healthy, unprocessed foods. Direct competitors include restaurants like 715 that offer Italian-style fare.
IRJET - Design and Analysis of BAJA RollcageIRJET Journal
This document describes the design and finite element analysis of a roll cage for an all-terrain vehicle (ATV). The roll cage is designed to withstand forces from various impact directions. AISI 4130 steel is selected for its strength, durability, and weldability. The roll cage geometry is modeled in CAD software and analyzed in ANSYS for front, rear, side impacts and rollover. Front impact analysis at 7G deceleration showed a maximum von Mises stress of 623 MPa and a safety factor of 1.04, indicating the design is safe. Similar analyses were performed for rear and side impacts.
IRJET- Fatigue and Static Thermal Analysis of Brake Disc for SAE based CarsIRJET Journal
This document summarizes a study that performed fatigue and thermal analysis on a brake disc design for SAE-based cars. The authors used CATIA V5 to model the brake disc and ANSYS Workbench to perform coupled thermal-structural analysis. The analysis evaluated fatigue life, stress concentration, deformation, and thermal gradients under static and thermal loading conditions. The results showed maximum heat flux and temperature at the disc-pad contact region. High stresses occurred at hole regions due to stress concentration. Crack initiation was found to begin at the junction of holes where the lowest cross-sectional area results in highest stresses. The minimum fatigue life cycle was 8722.2 and maximum was 1x109 cycles.
IRJET-Analysis of Load Factors and Modes of Failure on Spur GearIRJET Journal
The document analyzes the load factors and modes of failure in spur gears. A finite element analysis is conducted to determine the load distribution factor in AGMA formulas for spur gears with different shaft misalignments. The 3D gear model is imported into ANSYS to calculate maximum bending and contact stresses using FEA. The results are then compared to analytical calculations to estimate the load distribution factor. Key factors influencing bending stress on gear teeth are also considered, including load distribution, stress concentration, and external factors.
Optimization and Comparison of Mono Leaf Spring using Different MaterialsIRJET Journal
The document presents a comparative study of mono leaf springs made from different materials, including steel, E-glass, Kevlar, and carbon fiber. Solidworks software was used to create solid models of the leaf springs and perform finite element analysis. The analysis found that Kevlar had the highest stress level but lowest displacement, while E-glass and carbon fiber had higher displacement but lower stress than steel. E-glass, Kevlar, and carbon fiber also exhibited lower strain and natural frequency than steel. However, the alternative materials provided significant weight reductions compared to steel, ranging from 74-82%. Overall, the study aimed to determine the most suitable material for mono leaf springs by comparing their mechanical behaviors under the same loading conditions
IRJET- Effect of Stiffened Element in Structural Behaviour of Steel Built...IRJET Journal
This document presents the results of an experimental study on the effect of different stiffening patterns on the structural behavior of steel built-up beams. Three beam models were tested: an unstiffened beam, a beam with longitudinal stiffeners, and a beam with an N-truss pattern stiffener. Testing results showed that the beam with the N-truss stiffener had the highest load carrying capacity at 42.2% more than the unstiffened beam and 23.04% more than the longitudinally stiffened beam. Deflections were also lowest for the N-truss beam. While more costly, the N-truss pattern provides significantly higher strength, making it preferable for applications requiring high load capacity.
STRESS ANALYSIS OF SPUR GEAR BY USING ANSYS WORKBENCHSumit Nagar
The document discusses analyzing the stress on a spur gear using ANSYS Workbench. It begins by providing background on different types of gears and power transmission systems. It then describes spur gears in particular, including their structure, functions, advantages, disadvantages, and applications. The document outlines the objectives of performing finite element analysis on a spur gear model to minimize stresses at critical locations, validate results with experimental data, and compare to theoretical analyses. The goal is to optimize the gear shape to reduce stresses.
Fatigue or Durability Analysis of Steering Knuckleijsrd.com
This document discusses fatigue or durability analysis of steering knuckles. It explains that structural components like steering knuckles need to withstand constant fluctuating loads over time. Fatigue analysis evaluates failure based on repeated loading rather than just material strength. Steering knuckles experience multiaxial loads from multiple directions from components like the strut mount, lower ball joint, and steering rod. Accurately analyzing fatigue damage requires identifying these multiaxial stresses. The document aims to analyze the random loads acting on a vehicle's steering knuckle under unstable road conditions.
Design of Flat belt, V belt and chain drivesDr. L K Bhagi
Geometrical relationships, Analysis of belt tensions, Condition for maximum power transmission, Characteristics of belt drives, Selection of flat belt, V- belt, Selection of V belt, Roller chains, Geometrical relationship, Polygonal effect, Power rating of roller chains, Design of chain drive, Introduction to belt drives and belt construction, Introduction to chain drives
IRJET- Experimental Stress Analysis of Worm Wheel used in Crate Washer GearboxIRJET Journal
This document describes an experimental stress analysis of a worm wheel used in a gearbox for a crate washer. The gearbox was experiencing failures of the worm wheel teeth due to excessive bending stresses. Both theoretical and experimental analyses were conducted. The theoretical analysis used Lewis' equation to calculate bending stresses. The experimental analysis used photo stress methods to directly measure stresses by applying loads that simulated actual operating conditions and observing colored fringe patterns with a polariscope. This allowed quantification of stresses at points of high stress. The analyses found the worm wheel's material and geometry were improperly selected for the application, leading to failures. The worm wheel was then redesigned with new material and geometry suitable for the required working conditions.
IRJET- A Critical Review on Bellow Part Removal FixtureIRJET Journal
This document provides a review of bellow removal fixtures. It begins with an abstract that describes bellows as flexible elements in expansion joints that absorb dimensional changes from forces and thermal expansion. It also describes fixtures as work holding devices that impact manufacturing quality, productivity and cost.
The document then reviews the design of bellow removal fixtures. It discusses key parameters like the fixture frame needing to be rigid to minimize deflection, fast clamping, and locating the workpiece with at least three fixed support points. It also reviews the "3-2-1" locating principle for prismatic parts. Finally, it concludes that fixtures are used for locating and holding workpieces, and that they are fixed to machines to aid mass production and reduce operator
IRJET-Split Casing Open Differential without Cross Pin and it’s Comparison wi...IRJET Journal
This document summarizes the design optimization of work roll chocks and backup roll chocks in a cold rolling mill. The current chocks were failing prematurely, resulting in production stoppages and costs. A 3D model of the chocks was created and analyzed using ANSYS software to determine stress distributions and critical areas under load. The design was iteratively optimized to reduce weight and material costs while maintaining structural integrity. The optimized design was found to reduce chock weight by over 10% and save $9,154.50 per chock based on material and production costs. Modal analysis confirmed the natural frequencies of the optimized design would not cause resonance issues. This new optimized chock design was concluded to provide improved life and cost
IRJET- Design and Durability Analysis of Ladder Chassis FrameIRJET Journal
This document summarizes a study that analyzed the design and durability of a ladder chassis frame for heavy-duty vehicles. The researchers designed the chassis frame model using PTC Creo software and analyzed it using Hypermesh FEA software. Their analysis subjected the frame to static loading conditions representing braking, cornering, and going over bumps. Initial results found the design passed normal loading but failed under high bump loading. The researchers then iteratively modified the design, focusing on reinforcing brackets, to improve strength and pass all loading conditions with safety factors above 1.
IRJET-Finite Element Analysis of Seat Belt Frame AssemblyIRJET Journal
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Impact of Misalignments on Root Stresses of Hypoid Gear Setsijceronline
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity.
One of the most important component in mechanical is Gear for the transmission of power with ease and with less friction. Its main aim is to transfer torque from one shaft to other. There are different kinds of gears namely spur gear, helical gears, worm gears etc. Gear drives are used for different kinds of machines like automobiles, metal cutting tools, material handling equipment’s, rolling mills, marine power plants etc. The friction and other losses in this type of power transmission equipment is comparatively very low. In this work a software called “MATLAB†is used to design a Spur Gear. MATLAB is widely used for lot of research purposes for obtaining accurate results and it has got a lot of built in functions which makes it versatile. It is a user friendly one and when executed it ask the inputs and performs the necessary design calculations and gives necessary output values. As computers are used to perform the task of gear design becomes simple, friendly and error free.
IRJET- Error Identification and Comparison with Agma Standard in Gears us...IRJET Journal
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A computer programme to determine the bending and pitting
1. Computer Engineering and Intelligent Systems www.iiste.org
ISSN 2222-1719 (Paper) ISSN 2222-2863 (Online)
Vol.5, No.3, 2014
50
A Computer Programme to Determine the Bending and Pitting
Stresses of Gears and the Effect of Varying the AGMA Stress
Equation Parameters on the Stress Values
Stephen Kwasi Adzimah*
, Issifu Ibrahim
Department of Mechanical Engineering University of Mines and Technology, Tarkwa Ghana P. O Box 237,
Tarkwa – Ghana *
E-mail the corresponding author: skadzimah@yahoo.com
Abstract
Gears are one of the most critical components in mechanical power transmission systems. The bending and
surface strength of the gear tooth are considered to be the main contributors for the failure of the gears in a gear
set. Thus, analysis of these stresses has become imperative in the area of research on gears to reduce errors and
omissions in order to prevent the failures, and therefore, optimize the design of gears. The objective of this
project is to write a computer programme developed from Microsoft Excel and Matlab softwares, the application
of which is aimed at reducing the errors and omissions when calculating the bending and pitting stresses using
the AGMA methodology effectively, efficiently and quickly in the design and analysis of spur and helical gears.
The procedures employed include extraction of all the figures from the various graphs, obtaining an equation of
the graphs extracted using the curve fitting tool function in Matlab and using the graph equations together with
other equations of AGMA. The computer programme has been tested successfully and it has been established
that its application is capable of determining the bending and pitting stresses of any spur and helical gears and
their corresponding safety factors using the AGMA methodology.
Keywords: Gears; Transmission system; Gear set; Bending and surface strength.
1. Introduction
The crucial requirement of effective power transmission in various machines, automobiles, elevators, generators,
ships, aircrafts, etc, has created an increasing demand for more accurate analysis of the characteristics of gear
systems. This rapid development of these heavy machines requires advanced application of gear technology
(Alemu, 2007).
From the design viewpoint, failure by bending of the teeth as well as pitting failure of tooth surfaces are the most
important criteria when designing a gears et because each gear tooth may experience billions of load cycles
(Stoker etal., 2010).
The manual method of analyzing and designing of spur and helical gears such as using a pen and a paper come
with a lot of inefficiencies apart from it being time consuming when the AGMA methodology is employed. This
increase in errors and spending so much time on calculating these stresses has therefore made it essential to have
a computer software that will be used to calculate the stresses effectively, efficiently and quickly.
2. American Gears Manufacturers Association (AGMA) Standpoint and Contribution to Gear
Manufacturing
2.1 Information about AGMA
AGMA is a voluntary association of companies, consultants and academicians with a direct interest in the design,
manufacture, and application of gears and flexible couplings (Anon., 2012). AGMA was founded in 1916 by
nine companies in response to the market demand for standardized gear products; it remains a member- and
market—driven organization to this day. AGMA provides a wide variety of services to the gear industry and its
customers and conducts numerous programs which support these services.
Some of these services and programs are
Standards: AGMA develops all U.S. gear related standards through an open process under the authorization of
the American National Standards Institute (ANSI) (Anon., 2012).ISO Participation: AGMA is Secretariat to
TC60, the committee responsible for developing all international gear standards. TC60 is an ISO (International
Organization of Standardization) committee.
Market Reports and Statistics: AGMA’s Operating Ratio Report, Wage & Benefit Survey, and Monthly Market
Trend Reports help you stay competitive by giving you up-to-date information on the gear industry (Anon.,
2012).
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The Marketing and Statistical Councils enhance your competitiveness by sharing information and by developing
creative solutions to common industry problems.
Gear Expo: This is the only trade show dedicated solely to the gear industry.
The AGMA Training School for Gear Manufacturing uses current technology to offer.
News Digest, AGMA’s quarterly newsletter, offers you timely, useful information you can use immediately
(Anon., 2012).
2.2 Gears under Consideration: Spur and Helical Gears
2.2.1 General Spur Gears
Spur gears are the most commonly used gear type. These gears have teeth parallel to the axis of the wheel as
shown in Fig.2.1 (Khurmi and Gupta, 2008). Spur gears are by far the most commonly available, and are
generally the least expensive. The basic descriptive geometry for a spur gear is as shown below.
Fig. 1 Spur Gear Fig. 2 Helical Gear
(Source: Suman, 2003) (Source: Suman, 2003)
2.2.1.1 Limitations
Spur gears generally cannot be used when a direction change between the two shafts is required.
2.2.1.2Advantages
Spur gears are easy to find, inexpensive, and efficient.
2.2.2 General Helical Gears
Helical gears are similar to the spur gear except that the teeth are at an angle to the shaft, rather than parallel to it
as in a spur gear. The resulting teeth are longer than the teeth on a spur gear of equivalent pitch diameter. The
longer teeth cause helical gears to have the following differences from spur gears of the same size:
Tooth strength is greater because the teeth are longer,
Greater surface contact on the teeth allows a helical gear to carry more load than a spur gear
The longer surface of contact reduces the efficiency of a helical gear relative to a spur gear.
Helical gears may be used to mesh two shafts that are not parallel, although they are still primarily use in parallel
shaft applications. Helical gears run quieter and have a greater strength hand capacity than spurs (Gretchen,
2001). The basic descriptive geometry for a helical gear is essentially the same as that of the spur gear, except
that the helix angle must be added as a parameter (Suman, 2003).
Limitations: Helical gears have the major disadvantage that they are expensive and much more difficult to find.
Helical gears are also slightly less efficient than a spur gear of the same size (see below).
Advantages of helical gears: Helical gears can be used on non-parallel and even perpendicular shafts, and can
carry higher loads than can spur gears (Suman, 2003).
2.3 Modes of Gear Failure
Gear failure can occur in various modes. If care is taken during the design stage itself to prevent each of these
failure a sound gear design can be evolved. The gear failure is explained by means of flow diagram in Fig.3.
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Fig. 3 Different Modes of Failure
(Source: Gopinath and Mayuram, 2010)
2.3.1 Scoring
Scoring is due to combination of two distinct activities: First, lubrication failure in the contact region and second,
establishment of metal to metal contact. Later on, welding and tearing action resulting from metallic contact
removes the metal rapidly and continuously so far as the load, speed and oil temperature remain at the same level
(Gopinath and Mayuram, 2010).
2.3.2 Wear
As per gear engineer’s point of view, the wear is a kind of tooth damage where in layers of metal are removed
more or less uniformly from the surface. It is nothing but progressive removal of metal from the surface.
Consequently, tooth thins down and gets weakened. Three most common causes of gear tooth wear are metal-to-
metal contact due to lack of oil film, ingress of abrasive particles in the oil and chemical wear due to the
composition of oil and its additives (Gopinath and Mayuram, 2010).
2.3.3 Pitting of Gears
Pitting is a surface fatigue failure of the gear tooth. It occurs due to repeated loading of tooth surface and the
contact stress exceeding the surface fatigue strength of the material. Material in the fatigue region gets removed
and a pit is formed. The pit itself will cause stress concentration and soon the pitting spreads to adjacent region
till the whole surface is covered. Subsequently, higher impact load resulting from pitting may cause fracture of
already weakened tooth. However, the failure process takes place over millions of cycles of running. There are
two types of pitting, initial and progressive (Gopinath and Mayuram, 2010).
2.3.4 Initial / Incipient Pitting
In the helical gear shown in Fig.4 pitting started as a local overload due to slight misalignment and progressed
across the tooth in the dedendum portion to mid face. Here, the pitting stopped and the pitted surfaces began to
polish up and burnish over. This phenomenon is common with medium hard gears. On gears of materials that run
in well, pitting may cease after running in, and it has practically no effect on the performance of the drive since
the pits that are formed gradually become smoothed over from the rolling action. The initial pitting is non-
progressive.
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Fig. 4 Initial Pitting
(Source: Gopinath and Mayuram, 2010)
2.3.5 Progressive or Destructive Pitting
During initial pitting, if the loads are high and the corrective action of initial pitting is unable to suppress the
pitting progress, then destructive pitting sets in. Pitting spreads all over the tooth length. Pitting leads to higher
pressure on the unpitted surface, squeezing the lubricant into the pits and finally to seizing of surfaces.
Fig.5 Tooth Surface Destroyed by Extensive Pitting Fig. 6 Whole Tooth is Destroyed by Extensive Pitting
(Source: Gopinath and Mayuram, 2010) (Source: Gopinath and Mayuram, 2010)
Tooth faces are subjected to pitting only in rare cases. Fig. 2.5 shows how in destructive pitting, pitting has
spread over the whole tooth and weakened tooth has fractured at the tip leading to total failure as in Fig.6.
2.3.6 Flaking / Spalling
In surface-hardened gears, the variable stresses in the underlying layer may lead to surface fatigue and result in
flaking (spalling) of material from the surface as shown in Fig.2.7
(a) (b)
Fig.7 Flaking / Spalling
(Source: Gopinath and Mayuram, 2010)
2.3.7 Pitting - Subsurface Origin Failure
Fig.8 shows the subsurface origin failure.
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Fig.8 Subsurface Origin Failure Fig.9 Surface Origin Failure
(Source: Gopinath and Mayuram, 2010) (Source: Gopinath and Mayuram, 2010)
2.3.8 Pitting - Surface Origin Failure
Failure modes in gear namely the surface origin failure is shown in Fig.9.
2.3.9 Progressive Pitting
The progressive pitting is shown in Fig.10.
(a) (b)
Fig. 10 Progressive pitting
(Source: Gopinath and Mayuram, 2010)
2.3.10 Pitting - Frosting
Frosting usually occurs in dedendum portion of the driving gear first and later on the addendum as shown in
Fig.11. The wear pattern doesn’t have normal metal polish but has etched-like finish.
Fig.11 Frosting Fig.12 Plastic Flow - Cold Flow
(Source: Gopinath and Mayuram, 2010) (Source: Gopinath and Mayuram, 2010)
Under magnification, surface reveals very fine micro-pits of 2.5µm deep. These patterns follow the higher ridges
caused by cutter marks. Frosting results from very thin oil film and some asperity.
2.3.11 Pitting Failure
Surface endurance strength determines the selection of dimensions and material for almost all gearing operating
under conditions of the best possible lubrication.
2.3.12 Plastic Flow – Cold Flow
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Plastic flow of tooth surface results when it is subjected to high contact stress under rolling cum sliding action.
Surface deformation takes place due to yielding of surface or subsurface material. Normally, it occurs in softer
gear materials. But it can occur even in heavily loaded case hardened gears. Cold flow material over the tooth tip
can be seen clearly in the bevel gear shown in the Fig. 12.
2.3.13 Tooth Fracture
Tooth fracture is the most dangerous kind of gear failure and leads to disablement of the drive and frequently to
damage of other components (shafts, bearings, etc.) by pieces of the broken teeth. Tooth breakage may be the
result of high overloads of either impact or static in nature, repeated overloads causing low-cycle fatigue, or
multiple repeated loads leading to high cycle fatigue of the material.
2.3.13.1 Tooth Breakage – Bending Fatigue
Bending fatigue failure occurs over a long period of time. The initiation of crack takes place at the weakest point,
normally at the root of the tooth or at the fillet where high stress concentration exists together with highest
tensile stress from bending or from the surface defects as shown in Fig.13. The crack slowly propagates over 80
to 90% of the life.
Fig. 13 Root Crack Fig. 14 Tooth Breakage
(Source: Gopinath and Mayuram, 2010) (Source: Gopinath and Mayuram, 2010)
Then crack propagates fast and suddenly results in fracture of the tooth as shown in Fig. 2.14. The fractured
surface will exhibit beach marks in the slow crack propagation region and brittle fracture behavior in sudden
fracture region. Since time taken for the failure is very long, it is known as high cycle fatigue.
2.3.13.2 Tooth Breakage – High Cycle Fatigue
The tooth breakage in case of high cycle fatigue is shown in Fig..15.
Fig. 15High Cycle Fatigue
(Source: Gopinath and Mayuram, 2010)
2.3.13.3 Tooth Breakage – Low Cycle Fatigue (Over Load)
Overload breakage or short (low) cycle fatigue causes stringy fibrous appearance in broken ductile material. In
harder materials this break has a more silky or crystalline appearance as shown in Fig.16.
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Fig.16 Low Cycle Fatigue (Over Load) Fig. 17 Bending Fatigue
(Source: Gopinath and Mayuram, 2010) (Source: Gopinath and Mayuram, 2010)
2.3.13.4 Tooth Breakage – Bending Fatigue
Fig.17 shows tooth fatigue by bending fatigue.
2.3.13.5 Tooth Breakage
Breakage is often due to load concentration along the tooth length as a result of errors in machining and
assembly or of large elastic deformation of the shafts; tooth wear leading to weakening of the teeth results in
increased dynamic loads. Shifting of sliding gears into mesh takes place without stopping the rotation of the
shafts. Cracks are usually formed at the root of the teeth on the side of the stretched fibers where the highest
tensile stresses occur together with local stresses due to the shape of the teeth. Fracture occurs mainly at a cross
section through the root of the teeth.
In the case of fatigue failure, the fracture is of concave form in the body of the gear; it is of convex form when
the failure is from overload. The teeth of herringbone or wide-face helical gears usually break off along a
slanting cross section. To prevent tooth breakage, the beam strength of the gear teeth is checked by calculations.
Fatigue pitting of the surface layers of the gear teeth is the most serious and widespread kind of tooth damage
that may occur in gears even when they are enclosed, well lubricated and protected against dirt (Gopinath and
Mayuram, 2010).
2.4 Analytical Methods of Gear Design
2.4.1 The Lewis Bending Equation
The design of gear strength is based on two models: bending stress and contact stress models. The former is
related to the stress at the gear base, while the latter is related to the wear at the contact surface. The bending
equation was introduced by Wilfred Lewis in 1892. Since then, this equation has remained the standard for gear
design (Budynas and Nisbett, 2011; Dudley,1984). Lewis calculated stress in the gear base using a cantilevered
beam under an applied bending moment. By using this simple model, an accurate bending stress could be
determined (Budynas and Nisbett, 2011). This calculation assumes that the load is applied at the location of the
pitch radius (Colbourne, 1987). In practice, however, contact between the gear and pinion occurs at various
locations during the rotation.
To derive the basic Lewis equation, refer to Fig.2.18, which shows a cantilever of cross-sectional dimensions F
and t, having a length l and a load Wt, uniformly distributed across the face width F. The section modulus I/c is
Ft 2/6, and therefore the bending stress is
(1.a)
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Fig. 2.18Gear Tooth as Cantilever Beam
(Source: Budynas and Nisbett, 2011)
Referring to Fig. 18, we assume that the maximum stress in a gear tooth occurs at point a. By similar triangles,
we can write
(1.b)
By rearranging Eq. (2.a)
(1.c)
If we now substitute the value of x from Eq. (2.b) in Eq. (2.c) and multiply the numerator and denominator by
the circular pitch p, we find
(1.d)
Letting y = 2x/3p, we have
(2)
This completes the development of the original Lewis equation. The factor y is called the Lewis form factor, and
it may be obtained by a graphical layout of the gear tooth or by digital computation (Budynas and Nisbett, 2011).
2.11.2 AGMA Stress Equations
Two fundamental stress equations are used in the AGMA methodology, one for bending stress and another for
pitting resistance (contact stress). In AGMA terminology, these are called stress numbers, as contrasted with
actual applied stresses, and are designated by a lowercase letter s instead of the Greek lower case σ. (Budynas
andNisbett, 2011).
The fundamental equations are
(SI unit) (3)
where (for SI units),
Wt
is the tangential transmitted load, (N); KOis the overload factor; Kvis the dynamic factor
Ksis the size factor; F (b) is the face width of the narrower member, (mm)
KHis the load-distribution factor; KB is the rim-thickness factor; (mt)is the transverse metric module. YJis the
geometry factor for bending strength (which includes root fillet stress-concentration factor Kf)
The fundamental equation for pitting resistance (contact stress) is
σ= (S.I)
(4)
where Wt, KO, Kv,Ks, Km, F, and b are the same terms as defined for Eq. (2.2).
For SI units, the additional terms are
ZEis an elastic coefficient,(√N/mm2);ZRis the surface condition factor
dw1is the pitch diameter of the pinion, (mm); ZIis the geometry factor for pitting resistance
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2.12 Matlab Programming Language
Matlab is a high-level language and interactive environment for numerical computation, visualization, and
programming. Using MATLAB, you can analyze data, develop algorithms, and create models and applications.
The language, tools, and built-in math functions enable you to explore multiple approaches and reach a solution
faster than with spreadsheets or traditional programming languages, such as C/C++ or Java (Anon., 2013). Fig
2.19 shows the interface of the Matlab programming language.
Fig.19 Interface of the Matlab Programming Language, IDE
(Source: Anon., 2013)
3. Application Architecture, its Development and Installation
3.1 AGMA Stress Calculator Tool (ASCT)
The AGMA Stress Calculator Tool (ASCT) is a software application that determines the bending and pitting
stresses of spur and helical gears and their corresponding factors of safety. This was designed using Matlab
R2012a, Microsoft excel and Microsoft word.
3.2 Application Architecture
The application is structured to operate with a little user interactions by taking off most of the manual processes
and automating them behind the scene, thereby reducing errors caused by human interactions.
The flow chart below shows the system architecture of the application. It shows a quick way for understanding
the development process for the system.
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A look at the system architecture above shows that the only input required by the application is the data given
which are loaded via the application interface. A click on “Solve variables” on the application interface displays
all the results.
3.2.1 Data Input for ASCT
The minimum input data required are: power (kW), pinion speed (rev/min), Brinell hardness material selection,
quality of gears, pinion life, reliability, diameter gears (mm) and teeth, module (mm), face width (mm) and type
of mesh. Fig. 21 shows the part of the software for loading data
3.2.2 Output of ASCT
The ASCT displays two main results. Firstly, it displays all the stress parameters which comprise the transmitted
load, reliability factor, dynamic factor, geometry factor, pitch-line velocity, etc. as shown on the left hand side in
Fig.21 below. Then finally, the pinion and the gear parameters which comprise of the bending and pitting stresses
and their corresponding factors of safety are also displayed.
3.3 Development of the Application Interface
Microsoft word was used to design the interface f the AGMA stress calculator tool (ASCT) as shown in Fig.21. It
was then developed with Matlab programming language using the GUIDE tools. The basic controls used for the
interface includes, Edit text, List boxes and button controls. The User Interface controls were bound to series of
script and functions that solve for all the parameters that will be used to determine the bending and pitting
stresses and their corresponding factors of safety.
Fig. 21 Part of the Software for Loading Data
Fig.20 Flow Chart of the Application Architecture
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Fig.22 The Software Interface
3.4 Installation of the Application Interface
As introduced earlier, the application (ASCT) was engineered in Matlab using the Matlab functions. After the
development of the application, it was built and packaged into windows executable file (i.e. .exe) which can be
run on any windows OS. The application however cannot run on non-windows OS like Mac OSX, Linux, etc.
The steps for using the application are outlined as follows;
The setup file must be run by the user for the installation of the software to be executed.
Upon installing it, an executable file and an icon is placed on the desktop which when opened, launches
the executable file from the Application folder of the target machine.
The application is called forth by the user by running the application icon file found on the desktop after
installing the application. On running it, the application launches the interface with the input data for
loading as shown in Fig 22.
4. Calculation Analyses
4.1 Solution of a Sample Question to be Compared with that of the Software
4.1.1 Sample Question
A 20o
spur pinion with 70 mm diameter and a module of 2.5 mm transmits 15 kW to a 210 mm diameter
gear. The pinion speed is 1200 rev/min, number of teeth of pinion and gear are 28and 84 respectively
and the gears are grade 1, 21 mm face width, through-hardened steel at 200 Brinell, uncrowned,
manufactured to a No. 10 quality standard, and considered to be of open gearing quality installation.
Find the AGMA bending and contact stresses and the corresponding factors of safety for a pinion life of
109
cycles and a reliability of 0.98.
All Solved Variables Solved Stress and Safety Values
Input Values
from Question
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4.1.2 Long - hand Solution
Data summarized from the question; Pressure angle, Фt=20o
; Module, m=2.5mm (0.0025m)’ Grade 1 gears,
through-hardened steel; Face width = b = 21mm (0.021m); Brinell hardness, HB=200; Quality number,
Qv=10; Open gearing installation; Pinion life=109
cycles; Pinion speed, np=1200rpm; Power, H=15kW;
Pinion diameter, dp=70mm (0.07m);
Gear diameter, dG=210mm (0.21m); Number of teeth of pinion, NP=28 teeth;
Number of teeth of gear, NG = 84 teeth
General stress equations
J
BH
t
SVO
t
Y
KK
bm
KKKWStressesBending
1
).( =σ (5)
Iw
RH
SVO
t
E
Zbd
ZK
KKKWZstressccontact
1
().(
1
=σ (6)
V
H
WLoaddTransmitte t
=,.
(7)
60
pp dn
V
π
=
(8)
where, V is the pitch-line velocity
60
)07.0)(1200(π
=V
; V=4.3982m/s; 3982.4
1015 3
x
W t
=
;Wt
=3410.4861N; Overload factors, KO
Assuming uniform power source and uniform driven machine, KO=1; ;Dynamic factor, Kv
B
A
VA
Kv )
200
(
+
=
(9)
A=50+56(1-B) and B=0.25(12-Qv (10)
Substituting the quality number Qv into the B equation and solving yields. A=50+56(1-0.3969) and B=0.25(12-
10 ; A=83.7736 and B=0.3969
Then we have
3969.0
)
7736.83
)3982.4200(7736.83
(
x
Kv
+
=
=1.1278
Size factor, KS; AGMA suggests KS=1 (Budynas and Nisbett, 2011), therefore KS= 1
Load distribution factor,KH;; KH =1+Cmc (CpfCpm+CmaCe) (11)
Cmc= 1, (uncrowned teeth); Cpf = b≤ 25mm= (12)
Cpf =0.005; Cpm=1 (straddle mounted pinion)Cma =A+BF+CF2
; (13)
A=0.247, B=0.0167, C=-0.765(10-4
); F= = =0.8268inches
Cma= 0.247 + 0.0167(0.8268) - 0.765(10-4
) (0.82682
); Cma=0.2608; Ce=1
KH = 1+1(0.005×1+0.2608×1), KH =1.2658; Rim thickness
Since the backup ratio is not known we assume KB=1; Bending-strength geometry factor, YJ
(YJ)p = 0.38 (from Fig.14-6in Budynas and Nisbett, 2011)
(YJ)G= 0.44 (from Fig.14-6in Budynas and Nisbett, 2011)
Elastic coefficient; ZE=191 (from Table 14-8 in Budynas and Nisbett, 2011)
Surface condition factor
Standard surface conditions for gear teeth have not yet been established. When a detrimental surface finish effect
is known to exist, AGMA specifies a value of ZR greater than unity (Budynas and Nisbett, 2011)..Therefore,
ZR=1; Surface strength geometry factor, Zi
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Speed ratio ,mG= = =3;
12
sincos
+
=
G
G
n
tt
I
m
m
x
m
Z
φφ
(For external gears) (14)
=
13
3
)1(2
20sin20cos
+
x
; ZI=0.1205
Bending strength, St (Grade 1 through –hardened steel); St=0.533HB+88.3 (15)
=0.533(200) +88.3; St=194.9 MPa; Stress cycle factors, YN and ZN
(YN)=1.3558N-0.0178
(for both pinion and gear) (16)
(YN) p=1.3558(109
)-0.0178
(YN) p=0.8999; (YN)G =1.3558( ; YN)G=0.91767
(ZN)=1.4488N-0.023
(for both pinion and gear) (17)
(ZN) p=1.4488(109
)-0.023
=0.85311; (ZN)G=1.4488( =0.87494; Hardness-ratio factor, Zw
ZW=1, ( )<1.2(from Budynas and Nisbett, 2011)
Contact-fatigue stress (grade 1, through-hardened steel); Sc=2.22(HB) +200 (18)
Sc=2.22(200) +200; Sc=644 MPa
Reliability factor; Yz=0.658-0.0759ln (1-R) (19)
Yz=0.658-0.0759ln (1-0.98); Yz=0.9549
Temperature factor, Yθ
For oil or gear-blank temperatures up to 250°F (120°C), use KT = Yθ = 1.0. For higher temperatures, the factor
should be greater than unity. Heat exchangers may be used to ensure that operating temperatures are
considerably below this value, as is desirable for the lubricant.(Budynas and Nisbett, 2011)..Therefore Yθ=1
Bending stresses for pinion, from equation (5)
(σ)p= ; (σ)p = 244.0454 MPa
Bending stresses for Gear
(σ)G= ; (σ)G = 210.766 MPa
Corresponding factor of safety for the pinion
SF= = = 0.7526 (20)
Corresponding factor of safety for the gear
9262.0
9549.0766.210
9177.09.194
=
×
×
=
××
×
=
Z
Nt
F
YY
YS
S
θσ
Pitting stresses for the pinion
(σc)= = 1001.4 MPa
Pitting stresses for the gear
(σC)G= = 1001.4 MPa
Corresponding factor of safety for the pinion
Zc
WNC
H
YY
ZZS
S
θσ
=
=
Corresponding factor of safety for the gear
Zc
WNC
H
YY
ZZS
S
θσ
=
= = 0.621607 (21)
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4.1.3 ASCT Solution
The software was used to solve the same example as above; these are the results captured in Fig.22
Fig.23 The Software Displaying the Results
Table 1 Results of the Solution of the Sample Question Compared with that of the Software
Solved Parameters MANUALLY ASCT
Transmitted Load, Wt 3410.4861 3410.4631
Pitch Line Velocity,V 4.3982 4.3982
Dynamic Factor,Kv 1.1278 1.1278
Load Distribution Factor,KH 1.2658 1.2658
Pinion Bending-Strength geometry factor,Yj 0.38 0.3818
Gear Bending-Strength geometry factor,Yj 0.44 0.43632
Bending strength, St (Grade 1) 194.9 194.9
Pinion Stress cycle factors, YN 0.9000 0.8999
Gear Stress cycle factors, YN 0.91767 0.91767
Pinion Stress cycle factors, ZN 0.85311 0.85312
Bending stresses for pinion 244.0454 242.887
Bending stresses for Gear 210.766 212.538
Bending factor of safety for the pinion 0.7526 0.756198
Bending factor of safety for the gear 0.9262 0.881243
Pitting stresses for the gear 1001.4 1001.24
Pitting factor of safety for the pinion 0.57455 0.574628
Pitting factor of safety for the gear 0.621607 0.589332
5 Conclusions and Recommendations
5.1 Conclusion
In conclusion, the following has been achieved:
An effective software for determining the bending and pitting stresses for spur and helical gears has
been developed.
Accurate results will be achieved when determining bending and pitting stresses of spur and helical
gears.
A lot of time will be saved in selecting parameters for a gear design.
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A system for studying the effects of varying one gear parameter on other parameters.
5.2 Recommendation
The application should be further developed to include the determination of the bending and pitting
stresses of bevel and worm gears since this project only focused on spur and helical gears.
It is strongly recommended for gear designers, lecturers and the like to use this software whenever
dealing with the bending and pitting stresses of spur , helical, bevel and worm gears, which are the basic
gears in operation and also for more complex gears like hypoid, spiral, novikoff and others.
6 References
Alemu, N, (2007),” Analysis of Stresses in Helical Gears by Finite Element Method”,
Published MSc Thesis,School of Graduate Studies of Addis Ababa University, 64pp.
Anon. (2012), Technical Publications Catalog, American Gear Manufacturers
Association, 1001 N. Fairfax Street, 5th Floor Alexandria, VA 22314—1560, 75pp
Anon. (2013), “Matlab”,Matlab Central,www.mathworks.com/products/matlab/.Accessed: March 14, 2013.
Budynas, R.G. and Nisbett, J.K. (2011), Shigley's Mechanical Engineering Design, 9th
edition, McGraw-Hill Company Publishers Inc. 1221 Avenue of the Americas, New York, NY 10020, 1088
pp.
Colbourne, J.R. (1987), The Geometry of Involute Gears, Springer- Verlag, pp.5-8
Dudley, D.W. (1984), Handbook of Practical Gear Design, McGraw-Hill Company
Publishers Inc., pp. 10-20
Gopinath, K.and Mayuram, M.M. (2010),"Machine Design II", Published Lecture Notes,
Indian Institute of Technology, Madras, 20 pp.
Gretchen, R. (2001),"Gear Manual", Published by Martin Sprocket and Gear, Inc., 62pp
Khurmi, R, S. and Gupta, J.K. (2008), A Text Book of Engineering Mechanics, S.Chand
and Company Publishers, Ram Nagar, New Delhi-110055, 1230pp.
Stoker, K, Chaudhuri, A and Kim, N.H,“Safety of Spur Gear Design under Non-Ideal
Conditions with Uncertainty”,Proceedings of the ASME International Design Engineering Technical
Conferences and Computers and Information in Engineering Conference, IDETC/CIE, August 15-18, 2010,
Montreal, Quebec, Canada pp. 1-5
Suman, M.M (2003), “Gear Classification”
http://www.mae.ncsu.edu/eischen/courses/mae415/docs.pdf,13pp.
APPENDIX
Code Used for the Application of the Software Interface
The code used for this project which was written in Matlab R2012a is as shown below. The code is to
calculate the bending and pitting stresses of spur and helical gears and their corresponding safety factors.
% --- Executes on button press to solve variables.
Function solve variables_Call back(h Object, event data, handles)
%0h Object handle to solve_variables (see GCBO)
% event data reserved - to be defined in a future version of MATLAB
% handles structure with handles and user data (see GUIDATA
global ZE A B C YJpYJgZEgZEp Ko YNpYNgZNpZNg mg ZI phi gear_type V Wt ...
Kv Cmc Cma Cpm Cpf Ce F KH KB mt Zr Kr dw1 Ks pBSgBSpPSgPS grade gStpSt ...
YtgScpSc Zw pBSFgBSFpSHgSH
% k = (get(handles.listbox1,'String'));
K = cell(0,1);
k2=cell(0,1);
selected_row=get(handles.gear_condition,'Value');
allstrings=get(handles.gear_condition,'String');
in put value = all strings (selected_row);
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Vol.5, No.3, 2014
65
% Read the CMA CONDITION TABLES
[A B C]=cma_condition(inputvalue{1:end});
% Read the Elastic coefficient (ZE)
mrow=get(handles.pinion_material,'Value');
mcol=get(handles.gear_material,'Value');
ZEg= Elastic_coefficient_ZE(mrow,mcol);
ZEg=ZEg * 1000;
ZEp=Elastic_coefficient_ZE(mrow,7);
% Read the Overload Factor (Ko)
mrow=get(handles.power_source,'Value');
mcol=get(handles.driven_machine1,'Value');
Ko = overlaod_factor_ko(mrow,mcol);
% Solve for the Geometry Factor of Pinion
pteeth=str2double(get(handles.pinion_teeth,'String'));
gteeth=str2double(get(handles.gear_teeth1,'String'));
YJp= yj(pteeth, gteeth );
YJg= yj(gteeth, pteeth );
% Read the mg value
pdiameter=str2double(get(handles.pinion_diameter,'String'));
gdiameter=str2double(get(handles.gear_diameter,'String'));
mg=mg_value(gteeth,pteeth,gdiameter,pdiameter);
% Solve for Stress Cycle Factors (bending) of Gear n Pinion
P Load Cycle=str2double(get(handles.pinion_life,'String'));
hb=str2double (get (handles.hb_p,'String'));
YNp=Stress_Yn (hb, pLoad Cycle);
YNg=Stress_Yn (hb, pLoad Cycle/mg );
%Solve for Pitting Stress Cycle Factor of Gear and Pinion
ZNp = Stress_ZN(pLoadCycle );
ZNg = Stress_ZN(pLoadCycle/mg );
% Solving for Surface Strength Geometry factor (ZI)
gear_type = get (handles.gear_type,'Value');
phi=str2double(get (handles.pressure_angle,'String'));
ZI=ZI value (gear type, mg, phi);