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Optimization of Gear To Improve Performance of Gearbox

The document summarizes the optimization of a spur gear to improve the performance of a gearbox. It describes modeling a spur gear in Creo software and performing finite element analysis (FEA) in ANSYS to analyze stress and deflection. Parametric optimization is then conducted in Minitab by varying the pitch circle diameter, hole diameter, and number of holes. The analysis found that a gear with a 31 mm pitch circle diameter, 5 mm hole diameter, and 8 holes provided a 9.67% weight reduction while maintaining adequate strength based on the FEA results.

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Chandrakiran Alapati
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141 views4 pages

Optimization of Gear To Improve Performance of Gearbox

The document summarizes the optimization of a spur gear to improve the performance of a gearbox. It describes modeling a spur gear in Creo software and performing finite element analysis (FEA) in ANSYS to analyze stress and deflection. Parametric optimization is then conducted in Minitab by varying the pitch circle diameter, hole diameter, and number of holes. The analysis found that a gear with a 31 mm pitch circle diameter, 5 mm hole diameter, and 8 holes provided a 9.67% weight reduction while maintaining adequate strength based on the FEA results.

Uploaded by

Chandrakiran Alapati
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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International Journal of Advanced Engineering Research and Technology (IJAERT) 202

Volume 4 Issue 6, June 2016, ISSN No.: 2348 – 8190

OPTIMIZATION OF GEAR TO IMPROVE PERFORMANCE OF


GEARBOX
Krunalkumar Makwana*, Purnank Bhatt**
*PG Student, Silver Oak College, Ahmedabad, India
**Asst. Professor, Department of Mechanical Engineering
Silver Oak College, Ahmedabad, India

ABSTRACT No. of teeth (N) = 25


The goal of gear optimization is to decrease total mass of Pitch circle diameter(D) = 50mm
gears while assuring adequate stiffness. Optimization Pressure angle (φ) = 20
tools and computer simulations have gained the Module= 2 mm
paramount importance in industrial applications as a Tooth thickness (t) = 3.14mm
result of innovative designs, reduced weight and cost Root fillet = 0.628mm
effective products. In this work we use software called Addendum diameter (Ad) = 54mm
“Creo.2” to model a gear, ANSYS for optimization and Dedendum diameter (Dd) = 45mm
MINITAB for parametric optimization. These are Base circle diameter (Db) = 46.984mm
extensively used for scientific & research purposes. It is Yield Tensile Strength= 250 Mpa
accurate & also has a number of built in functions which Material used: Structural Steel
makes it versatile.
Do not underline any of the headings, or add dashes,
Keywords - gear optimization, performance of gearbox colons, etc.

I. INTRODUCTION III. DESIGN PROCEDURE

The design and optimization of gears is a highly First of all, the design tangential tooth load is
complicated task, and the need to develop light weight, obtained from the power transmitted and the pitch
quiet and more reliable designs has resulted in a variety
line velocity by using the following relation:
of changes in the design process. For transmission of
power, gears have been in use since the dawn of
civilization. Gears in the early stages were in the form of WT = ......................i.e (1)
cylindrical discs having surface irregularities. These
primitive transmission tools were adequate to meet the
operational needs of those days. Ancient engineers were Where WT = Permissible tangential tooth load
aware of the desired performance parameters such as a in newton,
gear ratio, centre distance and available power source P = Power transmitted in watts,
(water current, wind, horse power) and used them to
define the gear parameters (diameters, number and shape v = Pitch line velocity in m / s v =
of the teeth). πDN/60

II. SPUR GEARS SPECIFICATION D = Pitch circle diameter in meters


Here, presenting the calculations for the involute spur
gear of gearbox of windsmith state of the art company
From equation (1) we get
for stress reduction studies.
Model No: 917 WINDSMITH STATE of ART single
Spur gear RPM = Input RPM/G.R
reducer gear box
Horse Power: 0.14 hp = 200
Input RPM: 2000
Gear Ratio: 10 v = 0.52 m/s
Gear type: Spur gear
Gear specification: = 3.18 revolution/s

www.ijaert.org
International Journal of Advanced Engineering Research and Technology (IJAERT) 203
Volume 4 Issue 6, June 2016, ISSN No.: 2348 – 8190

= 1144.8 degree/s

= 20 rad/s

WT = 200 N

IV. MODELLING INVOLUTE SPUR GEAR

Fig 2. Boundary Condition

Figure 3 shows von mises stress distribution. Average


stress is around 30 Mpa and maximum stress at fillet is
106.16 Mpa which is safer side.
Fig.1. Modeling of spur gear

Following are the parametric equation.

Base_circle_radius=46.984/2

Angle=t*90

Cir_len= (PI*Base_circle_radius*t)/2

X_ins=Base_circle_radius*cos (Angle)

Y_ins=Base_circle_radius*sin (Angle)
Fig. 3 Von-Mises stress of gear
X=X_ins+ (Cir_len*sin (Angle))
Figure 4 shows total deflection of teeth which is
Y=Y_ins-(Cir_len*cos(Angle)) 0.0041143 mm.
Z=0

V. FEA OF GEAR

After completing gear model in CREO, file is called as a


IGES in ANSYS software for analysis purposes.
As shown in fig.2, boundary condition is applied. Load
on teeth the load is being transmitted from one gear to
another, it is all given and taken by one tooth, so 200 N
load is consider as a point load and applied on one teeth.
Also rotational velocity 20 rad/s is applied and gear is
considered fixed at centre part.

Fig. 4 Total deflection of gear

www.ijaert.org
International Journal of Advanced Engineering Research and Technology (IJAERT) 204
Volume 4 Issue 6, June 2016, ISSN No.: 2348 – 8190

VI. PARAMETRIC OPTIMIZATION Results of FEA are analysed using Minitab. Minitab
offers four types of designed experiments: factorial,
As per optimization we can conclude that hole diameter, response surface, mixture, and Taguchi (robust). After
pitch circle diameter and number of hole play major role conducting the analysis and entering the results, Minitab
in optimization. provides several analytical and graphing tools to help
Following possible value of hole diameter, pitch circle understand the results. Taguchi designs experiments
diameter and number of hole is selected based on using especially constructed tables known as
geometry of gear. “orthogonal arrays” (OA).The use of these tables makes
Pitch circle diameter: 26,31,36,41 mm the design of experiments very easy and consistent.
Number of hole: 04,06,08,10 Out of 16 analysis, Sr no 8 analysis gives the
Hole diameter: 02,03,04,05 mm best optimization based on weight reduction is 9.67 %
for the same capacity of gear which having 31 mm of
Here we have total three parameters and four values of pitch circle diameter, 5 mm of hole and 8 number of
each parameter. So total 34 = 81 solution is possible. So hole. Maximum weight reduction is 12.09 % of Sr. no 4
to reduced solution we need to go for parametric gear but in this case stress of gear is increased. So for the
optimization. same capacity or stress L8 analysis is selected as best
optimum solution.
VII. RESULT

The Von-mises stress and deflection are measured for


each set of parameter using FEA in ANSYS, and the
Sr PCD Hole DIA No of Stress Displacement Weight % Weigh
No mm mm Holes Mpa mm gm Reduction
1 26 2 4 110.1 0.0046 39.71 0.77
2 26 3 6 128.63 0.0039 38.98 2.61
3 26 4 8 111.59 0.0048 37.55 6.19
4 26 5 10 124.78 0.0051 35.19 12.09
5 31 2 6 84.53 0.0038 39.56 1.16
6 31 3 4 112.51 0.0046 39.33 1.74
7 31 4 10 125.49 0.0048 36.93 7.74
8 31 5 8 102.31 0.0048 36.15 9.67
9 36 2 8 103.96 0.0046 39.40 1.55
10 36 3 10 126.83 0.0045 38.28 4.35
11 36 4 4 103.97 0.0047 38.78 3.09
12 36 5 6 105.68 0.0042 37.12 7.25
13 41 2 10 133.69 0.0046 39.25 1.93
14 41 3 8 110.91 0.0050 39.06 2.42
15 41 4 6 157.92 0.0052 38.98 2.61
16 41 5 4 161.77 0.0060 39.08 2.37

out best optimum solution. The stress and deflection of


The Finite Element Analysis using ANSYS modified spur gear comes within safe limit. Overall near
software for spur gear was made for determination of about 10 % weight of spur gear is reduced. Good
stress and deformations. Also optimization of spur gear agreement between predicted and measured results was
with circular shape of hole at different PCD is done. For obtained for spur gear.
the parametric optimization MINITAB is used to find

www.ijaert.org
International Journal of Advanced Engineering Research and Technology (IJAERT) 205
Volume 4 Issue 6, June 2016, ISSN No.: 2348 – 8190

REFERENCE

[1] Faisal.S. Hussain, Syed Mohiuddin, Sajid Siddiqui,


R.N. Dehanka , “A Study on Optimized Design of a
Spur Gear Reduction Unit” , IOSR Journal of
Mechanical and Civil Engineering, 2014.

[2] Carlos H. Wink and Nandkishor S. Mantri, “Gear


Design Optimization for Low Contact Temperature of a
High-Speed Non-Lubricated Spur Gear Pair”, the
American Gear Manufacturers Associatio, 2013.

[3] Bhatt Parth, “A review on design, analysis and


material optimization of high speed helical gear by
changing deferent design parameters using FEA
approach”, International Journal of Engineering Sciences
& Research Technology, 2015.

[4] Syed Ibrahim Dilawer, Md. Abdul Raheem Junaidi,


Dr.S.Nawazish Mehdi, “Design, Load Analysis and
Optimization of Compound Epicyclic Gear Trains” ,
American Journal of Engineering Research, 2013.

[5] Haider M. Mohammad and Farah M. Abdul Razzaq,


“Optimization of Sustainable Spur Gears
Manufacturing”, International Journal of Current
Engineering and Technology, 2015.

[6] Xueyi Li, Shoubo Jiang and Qingliang Zeng,


“Optimization of Two-Stage Cylindrical Gear Reducer
with Adaptive Boundary Constraints”, Journal Of
Software, Vol. 8, No. 8, August 2013.

www.ijaert.org

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