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Design, Modelling and Structural Analysis of Helical Gear for ceramic and
steel material by using ANSYS

Conference Paper · December 2014

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 Design, Modeling and Structural Analysis of Helical Gear for ceramic and steel material by using ANSYS |ICEMS-2014

Design,Modaling and Structural Analysis of

Helical Gear for ceramic and steel material by
using ANSYS
Niyamat.A.Mullaa*, K.Bicha b, A.N.R. Reddyc
a
M.Tech Student, bAssistant Professor, cAssociate Professor& HOD
Dept. of Mechanical Engineering, MallaReddy College of Engineering & Technology, Hyderabad, Telangana, India.
a*
[email protected]

Abstract— This project mainly deals with the design and rotation, but are set at an angle. Since the gear is curved,
analysis of helical gear with involutes profile. The involutes this angling causes the tooth shape to be a segment of a
gear profile is the most commonly used system helix. Helical gears can be meshed in a parallel or crossed
for gearing today. In an involutes gear, the profiles of the orientations. The former refers to when the shafts are
teeth are involutes of a circle. In involutes gear design contact parallel to each other; this is the most common orientation.
between a pair of gear teeth occurs at a single instantaneous
In the latter, the shafts are non-parallel. The angled teeth
point. Rotation of the gears causes the location of this contact
point to move across the respective tooth surfaces. The teeth engage more gradually than do spur gear teeth causing
on helical gears are cut at an angle to the face of the gear. them to run more smoothly and quietly. With parallel
When two teeth on a helical gear system engage, the contact helical gears, each pair of teeth first make contact at a single
starts at one end of the tooth and gradually spreads as the point at one side of the gear wheel; a moving curve of
gears rotate, until the two teeth are in full engagement .This contact then grows gradually across the tooth face to a
gradual engagement makes helical gears operate much more maximum then recedes until the teeth break contact at a
smoothly and quietly than spur gears. For this reason, helical single point on the opposite side. In spur gears teeth
gears are used in almost all power transmissions. One suddenly meet at a line contact across their entire width
interesting thing about helical gears is that if the angles of the
causing stress and noise. Spur gears make a characteristic
gear teeth are correct, they can be mounted on perpendicular
shafts, adjusting the rotation angle by 90 degrees. Under this whine at high speeds and cannot take as much torque as
project the Helical gear with involutes profile is designed with helical gears. Whereas spur gears are used for low speed
the help of CATIA V5R16 software , modal and static applications and those situations where noise control is not
structural analysis is carried by the ANSYS software . a problem, the use of helical gears is indicated when the
application involves high speeds, large power transmission,
or where noise abatement is important. The speed is
Keywords— Gear Specification, Gear modeling, Modal & considered to be high when the pitch line velocity exceeds
Structural analysis 25 m/s Quite commonly helical gears are used with the
I. INTRODUCTION helix angle of one having the negative of the helix angle of
the other; such a pair might also be referred to as having a
Gears are most commonly used for power right-handed helix and a left-handed helix of equal angles.
transmission in all the modern devices. These toothed The two equal but opposite angles add to zero: the angle
wheels are used to change the speed or power between between shafts is zero – that is, the shafts are parallel.
input and output. They have gained wide range of Where the sum or the difference (as described in the
acceptance in all kinds of applications and have been used equations above) is not zero the shafts are crossed. For
extensively in the high-speed marine engines. In the shafts crossed at right angles the helix angles are of the
present era of sophisticated technology, gear design has same hand because they must add to 90 degrees.
evolved to a high degree of perfection. The design and
manufacture of precision cut gears, made from
materials of high strength, have made it possible to A. Helical Gear Nomenclature
produce gears which are capable of transmitting Helix angle, ψ
extremely large loads at extremely high circumferential Angle between a tangent to the helix and the gear axis. Is
speeds with very little noise, vibration and other zero in the limiting case of a spur gear.
undesirable aspects of gear drives. A gear is a toothed Normal circular pitch, pn
wheel having a special tooth space of profile enabling it to Circular pitch in the plane normal to the teeth.
mesh smoothly with other gears and power transmission Transverse circular pitch, p
takes place from one shaft to other by means of successive Circular pitch in the plane of rotation of the gear.
engagement of teeth. Gears operate in pairs, the smallest of Sometimes just called "circular pitch". pn = pcos(ψ)
the pair being called “pinion” and the larger one “gear”.
Usually the pinion drives the gear and the system acts as a
speed reducer and torque converter.

II. HELICAL GEAR SPECIFICATION

Helical gears offer a refinement over spur gears. The
leading edges of the teeth are not parallel to the axis of
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 Design, Modeling and Structural Analysis of Helical Gear for ceramic and steel material by using ANSYS |ICEMS-2014

interior surface representation and has quite a lot of

workbenches that make available KBE support(1).

Before creating helical gear we should know the

specifications of helical gear based on the data and
formulas we can design the helical gear.

Specification of Helical gear

rb - base cylinder radius
r - pitch circle radius
rk - outside circle radius
rf - root radius
Fig: 1 helical gear nomenclature a - pressure angle (20deg)
m – Modulo (in our example 20) m=p/3.14159
B. Helical gear geometric propotion where p is circular pitch 2r=m*z
z - Number of teeth (in our example 30)
 p = Circular pitch = d g. p / z g = d p. p / z p
 p n = Normal circular pitch = p .cosβ The following figure shows complete helical gear model
 P n =Normal diametrical pitch = P /cosβ which is generated by using CATIA and then it is retrieved
 p x = Axial pitch = p c /tanβ into ANSYS using IGES files.
 m n =Normal module = m / cosβ
 α n = Normal pressure angle = tan -1 ( tanα.cos β )
 β =Helix angle
 d g = Pitch diameter gear = z g. m
 d p = Pitch diameter pinion = z p. m
 a =Center distance = ( z p + z g )* m n /2 cos β
 a a = Addendum = m
 a f =Dedendum = 1.25*m

Fig: 3 shows Designed helical gear

IV. ANSYS
The ANSYS Workbench platform is the framework
upon which the industry’s broadest and deepest suite of
advanced engineering simulation technology is built. An
innovative project schematic view ties together the entire
simulation process, guiding the user through even
complex multi physics analyses with drag-and-drop
simplicity. With bi-directional CAD connectivity,
powerful highly-automated meshing, a project-level
Fig: 2 Tool used in gear geometry update mechanism, pervasive parameter management and
integrated optimization tools, the ANSYS Workbench
platform delivers unprecedented productivity, enabling
III. MODELING OF HELICAL GEAR USING CATIA Simulation Driven Product Development. In this project
It was developed by Dassault Systèmes in 1981 and it ANSYS 13.0 played a major role, all the analysis was
is located in French. Versions of CATIA are V1, V2, V3, done with the implementation of ANSYS. Mainly Modal
V4, V5 and V6 more companies are using from V4 only. ANSYS and Static Structural ANALYSIS were done in
Now in the market many companies are using V5R16 and this Project.
in V5 we have many versions from V5R1 to V5R21.It is a
tool based software these tools we call as features, so it is a A. Modal Analysis
feature based software .It is a parametric software,
In this Modal ANSYS, only the deformation of the
parametric mean while designing or after completing the
component was calculated with applying forces and
design we can change the parameters of the component.
boundary conditions. The deformation will be calculated
CATIA stand for Computer Aided Three Dimensional
at different natural frequencies and it was mentioned as
Interactive Application. It is a product modeling software
different modes. Applying of the boundary conditions will
can be custom-made via Application Programming
give you the specified directional deformation along with
Interfaces (API). CATIA V5 features are parametric
solid/surface-based wrap up which uses NURBS as the

122
 Design, Modeling and Structural Analysis of Helical Gear for ceramic and steel material by using ANSYS |ICEMS-2014

the total deformation.In this section modal analysis is

done by using ANSYS and which is shown in result table.

B. Structural Analysis
After the preprocessing, the solution has to be done. From
solution phase, choose the new analysis as static. Then
solve the current load step option. The solution will be
done. A model is generated using CATIA software and
then it is retrieved into ANSYS using IGES files. Fig: 4.5 Total deformations at 500 Mpa

In this section the Structural analysis is to be done .The

following Figure shows total deformation of gear, the Structural Analysis for Structural Steel
structural analysis of helical gear for aluminum and steel at
load 100Mpa, 200Mpa, 300Mpa, 400 Mpa, 500 Mpa.

Structural Analysis for Aluminum

Fig: 4.6 Total deformations at 100 Mpa

Fig: 4.1 Total deformations at 100 Mpa

Fig: 4.7 Total deformations at 200 Mpa

Fig: 4.2 Total deformations at 200 Mpa

Fig: 4.8 Total deformations at 300 Mpa

Fig: 4.3 Total deformations at 300 Mpa

Fig: 4.9 Total deformations at 400 Mpa

Fig: 4.4 Total deformations at 400 Mpa

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 Design, Modeling and Structural Analysis of Helical Gear for ceramic and steel material by using ANSYS |ICEMS-2014

VII. FUTURE SCOPE OF THE WORK

1. In the present investigation of static analysis, a

high speed helical gear is analyzed by fem
package ansys.

2. As a future work, modal analysis and harmonic

analysis of the gear can be performed to find out
Fig: 4.10 Total deformations at 500 Mpa the mode

V. RESULTS Acknowledgment
The analysis is carried out by ANSYS. The following
I have great pleasure in presenting this paper on
First table shows the modal analysis and second table
“Design, Modal and Structural Analysis of Helical Gear
shows the comparison of equivalent stresses & Total
for Ceramic and Steel material by Using ANSYS”. I take
deformation for aluminum and Structural steel.
this opportunity to express sincere appreciation and deep
sense of gratitude to my project guide, Assist Prof. K.
Table: 1 Modal Analysis
Bicha, MRCET, Hyderabad. For his whole hearted co-
operation, valuable guidance and perpetual encouragement
Equivalent Stresses Total Deformation and inspiration during the path of his work. I remain ever
S.No indebted to him for the keen interest shown and moral
(Mpa) (mm)
support offered all through pursuance of this work. I would
1 3609.7 7.0487 like to express my gratitude to M.Amarnadha Reddy
2 4346.2 10.334 Professor, Head of the Department of Mechanical
3 4346.7 10.338 Engineering for their support and valuable suggestions
4 4668.9 7.1834 during this work.
5 5243.8 11.19
6 5244 11.189 I would also like to thank all the supporting staff of the
Dept. of MECHANICAL and all other departments who
have been helpful directly or indirectly in making the paper
success.
Table-2 Comparison of equivalent stresses & Total
deformation between aluminum and structural steel I would like to express my high regards, sincere thanks and
L profound gratitude to all my family members specially my
Equivalent stress Total Deformation
S O
(Mpa) (mm)
mother for their moral support and blessings.
. A
N Aluminu
D Structur Aluminu Structural
m al Steel m Steel
References
1 100 0.81445 2.2572 0.00055919 0.000556 [1] Thirupathi r. Chandrupatla & ashok d.belegundu ., introduction to
2 200 3.2578 9.0288 0.0022368 0.002229 finite eleement in engineering, pearson ,2003
[2] Joseph shigley, Charles mischike ., mechanical engineering design,
3 300 7.3301 20.315 0.0050327 0.050127 tmh,2003
4 400 13.031 30.115 0.008947 0.008911 [3] Maithra ., handbook of gear design,2000
[4] V.b.bhandari., design of machine elements,tmh,2003
5 500 20.361 56.43 0.01398 0.013924 [5] R.s.khurmi ., machine design, schand,2005
[6] Darle w dudley.,hand book of practical gear design,1954
[7] Alec strokes., high performance gear design,1970
VI. CONCLUSION [8] Www.matweb.com
[9] Standards in spur and helical gears with FEM based verification,”
1. From the tables, it is observed that bending and ASME Journal of Mechanical Design,Vol 128/114
compressive stresses of ceramics are less than that [10] J.O.Nordiana, S.O.Ogbeide, N.N.Ehigiamusoe and F.I.Anyasi.,
2007,”Computer aided design of a spur gear, “Journal of
of the steel. Engineering and Applied Sciences 2 (12); pp 17431747.

2. Bending and compressive stresses were obtained

theoretically & by using ansys software for both
ceramic& steel.

3. Weight reduction is a very important criterion in

the helical gears.

4. Hence aluminum material is preferred.

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