Finite element analysis of spur gear

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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.
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