Finite element analysis of spur gear

Singh, Gagandeep

Finite element analysis of spur gear

Singh, Gagandeep

Permalink

Publication Type:: Thesis
Issue Date:: 2017

Open Access

Copyright Clearance Process

Recently Added
In Progress
Open Access

This item is open access.

Adobe PDF

Download contents and abstractAdobe PDF (286.77 kB)

Adobe PDF

Download thesisAdobe PDF (2.15 MB)

View statistics

Full metadata record

Field	Value	Language
dc.contributor.author	Singh, Gagandeep
dc.date.accessioned	2017-09-13T02:42:37Z
dc.date.available	2017-09-13T02:42:37Z
dc.date.issued	2017
dc.identifier.uri	http://hdl.handle.net/10453/116924
dc.description	University of Technology Sydney. Faculty of Engineering and Information Technology.	en_AU
dc.description.abstract	This thesis evaluates the service life of the spur gear in industry, showing that innovative techniques are required to resolve the problem of gear failure that occurs due to flank surface pitting and tooth breakage. Such techniques involve theoretical calculation, finite element analysis, hardness testing and selecting the appropriate material for the spur gear. Calculations were performed to measure contact stress, bending stress, and safety factor of the spur gear. This was followed by a finite element analysis (FEA) and software simulation. Then, the hardness test to compare the hardness of the materials was conducted. The material for the spur gear is chosen based on its mechanical properties. In this dissertation, the mechanical properties of currently used material C45 is compared to a new material, 19MnCr5. The aim of the research was to increase the service life of the spur gear pair using suitable and reliable material. To expand the purpose of the study, attention has also been paid to the ISO 6336 standard-based calculation for the load-carrying capacity of the spur gear; FEA simulation using ANSYS software, and Rockwell hardness test were both conducted. From material analysis, the study found that the 19MnCr5 material has more fatigue strength, tensile strength, and better yield point as compared to C45 material. Also, through mathematical and FEA comparison, the study establishes that the gear designed with 19MnCr5 material fulfils the prescribed safety limits and would operate for its recommended service life. Furthermore, it is clear from a series of Rockwell hardness tests conducted, that after achieving higher hardness values by using 19MnCr5 rather than the C45 grade material, the gear would work without breakage. For future study, it is suggested that there is a need to assess the effect of stress distribution variance over the flank and root of the spur gears, as this aspect has not been covered in the current context. Also, the stresses over the sub-surface of the gear teeth should be investigated. Besides this, research to find compatible lubricants for 19MnCr5 material is also required. Finally, observed differences in the hardness value at the rim and the tooth of the gear call for deeper analysis of the hardness testing process.	en_AU
dc.format	Thesis (ME)
dc.language.iso	en_AU	en_AU
dc.relation	https://opus.lib.uts.edu.au/bitstream/10453/116924/7/02whole.pdf
dc.rights	info:eu-repo/semantics/openAccess
dc.rights	The author owns the copyright in this thesis including all reproduction and reuse rights for the work. The work may not be altered without the permission of the copyright owner. Attribution is essential when quoting or paraphrasing from this thesis.
dc.rights	au.edu.uts.lib/ppc
dc.subject	Spur gear.	en
dc.subject	Gear failure.	en
dc.subject	Flank surface pitting.	en
dc.subject	Tooth breakage.	en
dc.subject	Finite element analysis (FEA)	en
dc.subject	Software simulation.	en
dc.subject	19MnCr5 material.	en
dc.subject	Rockwell hardness tests.	en
dc.subject	Stress distribution variance.	en
dc.title	Finite element analysis of spur gear	en_AU
dc.type	Thesis	en_AU
utslib.copyright.status	open_access

Abstract:

This thesis evaluates the service life of the spur gear in industry, showing that innovative techniques are required to resolve the problem of gear failure that occurs due to flank surface pitting and tooth breakage. Such techniques involve theoretical calculation, finite element analysis, hardness testing and selecting the appropriate material for the spur gear. Calculations were performed to measure contact stress, bending stress, and safety factor of the spur gear. This was followed by a finite element analysis (FEA) and software simulation. Then, the hardness test to compare the hardness of the materials was conducted. The material for the spur gear is chosen based on its mechanical properties. In this dissertation, the mechanical properties of currently used material C45 is compared to a new material, 19MnCr5. The aim of the research was to increase the service life of the spur gear pair using suitable and reliable material. To expand the purpose of the study, attention has also been paid to the ISO 6336 standard-based calculation for the load-carrying capacity of the spur gear; FEA simulation using ANSYS software, and Rockwell hardness test were both conducted. From material analysis, the study found that the 19MnCr5 material has more fatigue strength, tensile strength, and better yield point as compared to C45 material. Also, through mathematical and FEA comparison, the study establishes that the gear designed with 19MnCr5 material fulfils the prescribed safety limits and would operate for its recommended service life. Furthermore, it is clear from a series of Rockwell hardness tests conducted, that after achieving higher hardness values by using 19MnCr5 rather than the C45 grade material, the gear would work without breakage. For future study, it is suggested that there is a need to assess the effect of stress distribution variance over the flank and root of the spur gears, as this aspect has not been covered in the current context. Also, the stresses over the sub-surface of the gear teeth should be investigated. Besides this, research to find compatible lubricants for 19MnCr5 material is also required. Finally, observed differences in the hardness value at the rim and the tooth of the gear call for deeper analysis of the hardness testing process.

Please use this identifier to cite or link to this item:

http://hdl.handle.net/10453/116924