International Journal of Mechanical Engineering and Technology (IJMET)

Volume 7, Issue 4, July–Aug 2016, pp.8–21, Article ID: IJMET_07_04_002

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ISSN Print: 0976-6340 and ISSN Online: 0976-6359
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STATIC AND DYNAMIC ANALYSIS OF

SPUR GEAR
Shubham A. Badkas and Nimish Ajmera
Mechanical Engineering Department,
Pune Vidyarthi Griha’s College of Engineering and Technology, Pune, India

ABSTRACT
Gear is the one of the important machine element in the mechanical power
transmission system. Spur gear is most basic gear used to transmit power
between parallel shafts. Spur gear generally fails by bending failure or
contact failure. This paper analyses the bending stresses characteristics of an
involute spur gear tooth under static loading conditions. The tooth profile is
generated using Catia and the analysis is carried out by Finite element
method using ANSYS software. The stresses at the tooth root are evaluated
analytically using existing theoretical models. The theoretical and FEM
results are compared. The results obtained theoretically are in good
agreement with those obtained from software. Also an attempt is made to
introduce Stress and displacement characteristics of tooth under dynamic
loading conditions.
Key words: Ansys, Bending stress & Deflection by FEA, Dynamic analysis,
Static analysis, Spur gear.
Cite this Article: Shubham A. Badkas and Nimish Ajmera, Static and
Dynamic Analysis of Spur Gear. International Journal of Mechanical
Engineering and Technology, 7(4), 2016, pp. 8–21.
http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=7&IType=4

1. INTRODUCTION
In the today’s world of industrialization Gears are the major means for the mechanical
power transmission system, and in most industrial rotating machinery. Because of the
high degree of reliability and compactness gears dominates the field of mechanical
power transmission. Gearbox is used to convert the input provided by a prime mover
into an output required by end application. Due to increasing demand for quiet and
long-term power transmission in machines, vehicles, elevators and generators, people
are looking for a more precise analysis method of the gear systems. Spur gear is the
most basic gear used to transmit power between two parallel shafts with almost 99%
efficiency. It requires the better analysis methods for designing highly loaded spur
gears for power transmission systems that are both strong and quiet. Due to
development of computers people are using numerical approach for the analysis

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 Static and Dynamic Analysis of Spur Gear

purpose as it can give more accurate analysis results. The finite element method is
capable of providing information on contact and bending stresses in gears, along with
transmission errors, which can be done easily in ANSYS software. Gear analysis in
the past was done by using analytical methods which requires complicated
calculations. Now with the use of FEA we can calculate the bending stresses in the
gear tooth for given loading condition and we can compare the FEA results with
existing models to decide the accuracy. Also static as well as dynamic, both loading
conditions of gear can be easily analyzed in Ansys which is not the case with
Analytical method.

2. PROBLEM DEFINITION
For this problem we are doing our calculations analytically and compare results with
software results. Any problem can be solved by following same procedure.

2.1. Question
The Following data is given for a spur gear pair made of steel and transmitting 5KW
power from an electric motor running at 720 rpm to a machine:
No. Of teeth on Pinion= 21, No. Of teeth on Gear= 40, Module= 5mm, Face
width= 10m, Ultimate Tensile Strength for Pinion material= 600 N/mm^2, Ultimate
Tensile Strength for Gear material= 400 N/mm^2, Tooth System =20 Degree Full-
Depth Involute, Service Factor =1.25, Load Concentration Factor = 1.6, Tooth Form
factor for pinion= .326, Tooth Form factor for gear= .389, Velocity factor= 6/ (6+v).

2.2. Solution
Beam Strength for pinion σ =Sut/3= 600/3 =200 N/mm^2 and for gear σ =Sut/3=
400/3 =133.34 N/mm^2. Now, σ *Yp = 200*.326= 65.2 N/mm^2 and σ * Yg =
200*.389= 51.87 N/mm^2.
As, Strength of gear < Strength of pinion, gear is weaker than pinion in bending.
Hence it is necessary to design the gear for bending.
Pitch Line Velocity (V) = π*Dp*Np/(60000)= 3.9585 m/s
Theoretical Tangential Force Ft= P/V= 5000/3.9585=1263.1047 N (approx. 1200N)

3. STATIC ANALYSIS
3.1. The Lewis Formula (Stress Calculation)
The analysis of bending stress in gear tooth was done by Mr. Wilfred Lewis in his
paper, ‘The investigation of the strength of gear tooth’ submitted at the Engineers club
of Philadelphia in 1892. Even today, the Lewis equation is considered as the basic
equation in the design of gears [1]. Wilfred Lewis was the first person to give the
formula for bending stress in gear teeth using the bending of a cantilevered beam to
simulate stresses acting on a gear tooth shown in Cross-section =b*t , height = h,
Load=Ft uniform across the face.

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 Shubham A. Badkas and Nimish Ajmera

Figure 1 Lewis Equation

Lewis considered gear tooth as a cantilever beam with static normal force F
applied at the tip. He took the critical
critical section as parabola through point ‘a’ and
tangent to tooth curves at the root as shown in fig.1. This parabola shown by dotted
line is a beam of uniform strength.
Assumptions made in the derivation are: 1.The The full load is applied to the tip of a
single
gle tooth in static condition,
condition 2.thehe radial component is negligible,
negligible 3.the load is
distributed uniformly across the full face width,
width 4.forces
orces due to tooth sliding friction
are negligible and 5.stress
tress concentration in the tooth fillet is negligible. In the current
analysis of spur gear we follow the Lewis assumptions and equation.
When the bending stress reaches the limiting value i.e. bending endurance
strength or permissible bending stress , the corresponding tangential force is called
the beam strength and given as
= ∗ ∗ ∗ (3.1).
Equation 3.1 is known as Lewis equation for beam strength of spur gear.

3.2 Derivation
n of Deflection for Gear Tooth
T using
sing Castigliano’s Theorem
Lewis has assumed parabola in the gear tooth. So we directly find the deflection of the
parabolic teeth with minor errors with actual deflection [2, 3]. We use the
castigliano’s theorem for the same

Figure 2 Parabolic Teeth

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 Static and Dynamic Analysis of Spur Gear

3.2.1. Castigliano’s Theorem

Castigliano’s theorem is one of the energy methods (based on strain energy) and it can
be used for solving a wide range of deflection problems.
Castigliano’s theorem states that when a body is elastically deformed by a system
of loads, the deflection at any point “P” in any direction “a” is equal to the partial
derivative of the strain energy (U) with respect to a load at “F” in the direction “a”.
The theory applies to both linear and rotational deflections

δ=
It should be clear that Castigliano’s theorem finds the deflection at the point of
application of the load in the direction of the load.

Strain energy is given by U = ( )dx

( ∗ ∗)
Consider the parabolic teeth of height ‘h’ and tooth thickness‘t’.
Equation of parabola is y = 4*a*x.
At x=h, y=t/2
Thus equation of parabola becomes (t/2 ) = 4*a*h.
a = t /(16 ∗ h)
Thus equation of parabolic teeth is y = (t /4 ∗ h)*x and y % = (t/2 )%*(x/h ) .'.

Thus strain energy of teeth becomes, U = ( )dx

( ∗ ∗)
M = F) *x & I = b*(2 ∗ y)% /12 = (2/3)*b*y %
/
(P ∗ x)
U=* ( )dx
(2 ∗ E ∗ (2/3 ∗ b ∗ y % ))
/
3(P ∗ x)
U=* ( )dx
4(E ∗ b ∗ y % )
Substituting value of y % we get
/
12 ∗ P ∗ h .' ∗ x^0.5
U=* ( )dx
E ∗ b ∗ t%
3∗4 ∗/5
U= ∗6∗)5
Now by castigliano’s theorem

δ=

78∗9∗:;
δ=
<∗=∗> ;
This is the expression for the maximum deflection of spur gear teeth tip when
tangential load is applied at the teeth tip.

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 Shubham A. Badkas and Nimish Ajmera

3.3. Analytical Results

3.3.1. Stress using flexure formula

The bending stress at the root of tooth can be given by flexure formula
@ ∗/∗()/ ) A∗ @ ∗/
σ= /?
= 6∗)5 /
= 6∗)
Tangential load(Ft)= 1200N(approx.),Height of tooth(h)=11.25mm, Face
Width(b)=50mm, Thickness(t)= 10.614mm(at root)...........(Using basic values of
various parameters).
Therefore, Stress (σ) = 6*1200*11.25/ (50*10.614^2)
Theoretical Stress (σ) = 14.3799 N/mm^2.

3.3.2. Deflection using Castigliano’s Theorem

A∗4∗/^%
Deflection (δ) =
∗6∗)^%
Tangential load(Ft)= 1200N, Face Width(b)=50mm, Thickness(t)= 10.614mm(at
root),Stiffness constant(E)= 206000 N/mm^2.( Using basic values for various
parameters).
Height of tooth (h) calculated using Lewis constant, as we required height of
parabola:-
B EF ∗G∗(H/ ) A∗EF ∗G
σ= = =
∗H 5 /
Comparing equations σ = Ft/ (b*m*Y) and
C/D ∗H
We get, Y = (t )/ (6*h)
Lewis constant Y=.389(given for gear), Module m= 5mm (given), Thickness=
10.614mm (at root)
Therefore, 389*5=10.614^2/ (6*h)
Height of parabola tooth (h) = 9.6535mm
Therefore, Deflection δ= 16*1200*9.6535^3/ (206000*50*10.614^3)
δ= .0014mm

3.4. Analysis by using Ansys

3.4.1. Ansys Procedure
The entire analysis is done on the single gear tooth in Ansys 14.0. For that purpose we
use the following procedure,

3.4.2. Discretization of Continuum

Draw gear tooth in catia of given dimensions→ Divide the gear tooth in 25 sections→
calculate mean thickness for each section. (Do not consider the fillet radius as
assumed by Lewis.)

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 Static and Dynamic Analysis of Spur Gear

Figure.3 Gear Tooth in Catia

3.4.3. Ansys modelling and Boundary Conditions

Import the IGS file of gear tooth in Ansys. Take element type as beam. Take 25 nodes
equidistantly on length equals to tooth height and create different sections of
calculated dimensions (length and breadth). Then create elements at nodes of
corresponding element attribute. One end of tooth is fixed and at other end tangential
load of 1200N (approx.) is applied at the tip. All boundary conditions are applied on
nodes.

Figure.4 Oblique View of Teeth

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 Shubham A. Badkas and Nimish Ajmera

3.4.4. Plotting stress and Deflection Graphs

For end conditions.

Figure.5 Von Mises Stress Plot (Top View)

Figure.6 Deflection Plot (Top view)

3.5. Ansys Results

1. Stress: As it can be seen from above images

Maximum Von Mises Stress= 14.3018 N/mm2

2. Deflection:- From above images Maximum Deflection = .0014 mm

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 Static and Dynamic Analysis of Spur Gear

3.6. Comparison of Results

esults
Stress
Sr. No. Ansys Analytical % Accuracy % Error
Stress(N/mm2) Stress(N/mm2)

1 14.3018 14.3799 99.45% .543%

Deflection
Sr. No. Ansys Deflection(mm) Analytical Deflection(mm)
1 .0014 .0014
As it can be seen from comparison that % error in stress is negligible and no error
in deflection of gear tooth calculated using element type as beam. So these the FEA
models are good enough for stress analysis of spur gear teeth in static condition

4. DYNAMIC ANALYSIS
4.1. Introduction to Dynamic Analysis
Dynamic load is defined as the load which varies in magnitude, direction or point of
application with respect to time. Dynamic load in the mechanical components causes
the generation of fluctuating stresses. In case of spur
spur gear the load acting on gear
tooth is constant in magnitude as well as in direction but varies in point of application
of load. Thus spur gear teeth are subjected to fluctuating stresses and lead to fatigue
failure. Gears are the important power transmitting
transmitting elements in mechanical system
and hence sudden failure of gear tooth may lead to danger. Therefore it is necessary to
perform the dynamic analysis of spur gear.

4.2. Load Distribution

Load distribution on gear tooth
to In order to conduct a dynamic stress analysis the loads
have to be evaluated.
aluated. The load on the tooth of the finite element model, which
produces the largest bending stress, is the full load acting at the highest point of single
tooth contact (HPSTC). The magnitude of load at any point of contact on profile of
gear tooth as the load moves from root to tip of tooth depends
depends on the contact ratio.
Fig. shows the contact path, the contact ratio CR is defined as the ratio of length of
path of contact
tact AB to base circle pitch Pb [4, 5].

Figure.7 Path of contact

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 Shubham A. Badkas and Nimish Ajmera

Figure.8 Load distribution

Contact ratio calculated as 1.64 which is approximately equal to 2. Now while
applying load we have considered 39 nodes on left edge of tooth numbered from 6 to
44. Bottom nodes left to consider the clearance
clearance and the load variation is assumed
symmetricc variation from bottom to top.

4.3. Time Step

The time of contact T of gear tooth depends on the rotational speed of the gear. If
the gear is assumed to run at a speed of n-rpm,
n rpm, the time taken for one revolution of the
gear will be (60/n) sec. In one revolution, Z number of teeth will get engaged and
A
disengaged. Thus contact time for 1 tooth is T = .
I∗J
As N=720 rpm (Pinion), Z=21(Pinion), thus T = 0.00397 sec.
Thus, time step for 40 nodes is T/40= 0.0000925 sec.
The Initial conditions for displacements and velocities for the gear tooth in the
proposed model are taken as zero for all degrees of freedom. We have assumed equal
time is required to transfer load from one node to other. For nodes 32 to 44 load=600
N (Half load), for nodes 19 to 31 load= 1200N (Full load) and for nodes 6 to 18 load=
600 N (Half load) is applied [5].
[5]

4.4. Ansys Procedure

• Draw gear tooth in catia→
catia Import IGS file in Ansys→ Choose element type as solid
solid-
plane 182(Quad 4 node 182) with element behaviour of plane stress with thickness
input as Lewis has assumed the load acting on tooth as uniformly distributed load and
this will generate plain stress condition at each cross section in of teeth of shown
orientation→ → Give its real constant
constant (thickness) and material properties (density,
young’s modulus and poisson ratio) →Create area→ Mesh (Fine meshing).. 2.
Loads→ new analysis→ transient analyse→ reduced methods→ → Master degree of
freedom→ user defined methodmethod→ select all nodes except nodeses which are on zero
displacement base line→
line apply boundary conditions on last line.
• Load Step opts→ → Time/frequency→
Time/frequency Time/Time-step option→ → Put Initial conditions
and load type- stepped→
stepped Write this LS file as 1→ start applying forces at various
nodes for a particular time→
time follow same procedure as mentioned above
above→ write this
file as 2→ Similarly apply forces at various nodes for different time and write there
file as 3, 4, 5.etc. → Solve-
Solve From LS files- LS file 1-41.

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 Static and Dynamic Analysis of Spur Gear

Figure.9 Meshed Tooth

Figure.10 Master DOF with Applied Force

• TimeHist PostPro→ adds data→ DOF Solution(X-component of displacement) →
Choose Node 1(Upper most node) → Graph Data to get following solution.
• Solution→ Analysis type→ Turn on Expansion Pass→ Load step options→
Expansion Pass→ Single Expand→ Range of solutions→ Solve→ Current LS- Ok to
solve.
• TimeHist PostPro→ Add data→ DOF Solution(X-component of displacement) →
Choose Node 1(Upper most node) to get expanded solution for displacement.

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 Shubham A. Badkas and Nimish Ajmera

Figure.11 X-Component of Displacement for Node 1

4.5. Results
• Displacement at any node at particular time during engagement can be calculated
For example. at Time= 0.42734E-02 sec displacement plot of teeth is

Figure.12 Displacement Plot of Teeth

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 Static and Dynamic Analysis of Spur Gear

• Displacement of particular node can be calculated for any time.

For example. for tip node displacement v/s time graph is

Figure.13 X-Component of Displacement for Node 1 (Expanded Solution)

• Stress at any node at particular time during engagement can be calculated

For example. At Time= 0.42734E-02 sec stress plot of teeth is

Figure.14 Stress Plot of Teeth

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 Shubham A. Badkas and Nimish Ajmera

• Stress of particular node can be calculated for any time

For example. For root node stress v/s time graph is:

Figure.15 Von Mises Stress v/s Time Graph

5. CONCLUSION
In this project an attempt is made to co-relate the bending stresses and displacement
of a spur gear tooth which are obtained analytically as well as by FEM. Recent
developments in the field of mechanical engineering are demanding refined gear teeth
in terms of loading capacities and speed with which they can operate. The static and
dynamic analysis of spur gear tooth helps to determine maximum displacement,
maximum induced stress and effect of stress variation with respect to time. The
loading capacity and operating speed of geared system can be increased by reducing
the maximum induced stresses.
The following conclusions can be drawn from the results obtained:
• The maximum stresses for gear teeth occur in the root region of gear tooth.
• Static analysis of spur gear tooth with element type as Beam give more accurate
results for maximum displacement and maximum induced stress. The accuracy of
stress calculated using FEA model and analytical calculations is 99.45% and that of
displacement is almost 100%. Thus we can conclude that beam element is more
suitable for static analysis of spur gear. This is in accordance with Lewis bending
stress calculation formula who has considered the gear tooth as cantilever beam.
• With the help of dynamic analysis the stress and displacement variation at any node
with respect to time and stress and displacement variation at any time instant for all
nodes can be known and corresponding results can be represented graphically. Nature
of graph can be used to predict force variation along tooth.
• Maximum value of stresses and displacement of dynamic analysis are obtained from
the graph are comparable with static analysis results. Hence FEM model is good
enough for dynamic stress consideration.

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 Static and Dynamic Analysis of Spur Gear

REFERENCES
[1] Prof. K.Gopinath & Prof. M.M.Mayuram,” Machine Design II”, Indian Institute
of Technology Madras.

[2] T.F.Hickerson,1952,”Beam Deflection When Moment Of Inertia Is Variable”,

Kenan Prof of Applied Mathematics, University of North Carolina Chapel Hill,
North Carolina.

[3] Prof. S. B. Naik, 2015,”Deflection Estimation of Varying Cross Section

Cantilever Beam” IJSRD - International Journal for Scientific Research &
Development| Vol. 2, Issue 11, 2015 2321-0613 Faculty Department of
Mechanical Engineering, Walchand Institute of Technology, Solapur,
Maharashtra, India

[4] American Gear Manufacturers Association “Geometry Factors for Determining

the Pitting Resistance and Bending Strength of Spur, Helical and Herringbone
Gear Teeth”, AGMA 908-B89 (Revision of AGMA 226.01), April 1989.

[5] Anand Kalani and Rita Jani, Increase in Fatigue Life of Spur Gear by
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Engineering and Technology (IJMET), 6 (5) 2015,pp. 82–91.

[6] Ali Raad Hassan, 2009,” Transient Stress Analysis on Medium Modules Spur
Gear by Using Mode Super Position Technique”, World Academy of Science,
Engineering and Technology International Journal of Mechanical, Aerospace,
Industrial, Mechatronic and Manufacturing Engineering Vol:3, No:5

[7] Sanjay K. Khavdu, Kevin M. Vyas, Comparative Finite Element Analysis of

Metallic Spur Gear and Hybrid Spur Gear. International Journal of Mechanical
Engineering and Technology (IJMET), 6 (4) 2015, pp. 117–125.

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