International Journal of Trend in Scientific Research and Development (IJTSRD)

Volume 7 Issue 6, November-December 2023 Available Online: www.ijtsrd.com e-ISSN: 2456 – 6470

Analysis of Stress and Deflection of Spur Gear

by Using New Analytical Method Based on
Taguchi Method and Finite Element Analysis
Khin Khin Thant, Than Than Htike
Mechanical Engineering Department, Yangon Technology University,
Insein Township, The Republic of the Union of Myanmar

ABSTRACT How to cite this paper: Khin Khin Thant

One of the most important measures of transmission performance is | Than Than Htike "Analysis of Stress
the gear tooth root stress (TRS). High root stress can directly damage and Deflection of Spur Gear by Using
the gear tooth and indirectly affect the life of the gear. This paper New Analytical Method Based on
Taguchi Method and Finite Element
considered reducing the stresses in the base of the change in the gear
Analysis" Published
profile. Accurate calculation of the maximum tooth root stress (TRS) in International
and deflection is fundamental to the prediction and optimization of Journal of Trend in
gears. The Finite Element Method (FEM) gives accurate results. But, Scientific Research
the calculation requires a lot of resources and time. Moreover, the and Development
results obtained from the Lewis, the ISO, and the AGMA methods (ijtsrd), ISSN:
were useful. This paper approved the results of the new method as 2456-6470, IJTSRD60165
useful as other methods. Therefore, in the current results, a new Volume-7 | Issue-6,
analytical method based on mechanic theory is created using exact December 2023, pp.404-410, URL:
profile equations to calculate stress and deflection. Firstly, the load www.ijtsrd.com/papers/ijtsrd60165.pdf
sharing ratio is considered using the Taguchi method. Finally, tooth
Copyright © 2023 by author (s) and
root stress and deflection are calculated from this profile. The result
International Journal of Trend in
of tooth root stress obtained from the new method is compared with Scientific Research and Development
the FEM method. The result of the new method is found the Journal. This is an
consistent with FEM method. Open Access article
distributed under the
KEYWORDS: deflection, load sharing ratio, spur gear, tooth root terms of the Creative Commons
stress (TRS) Attribution License (CC BY 4.0)
(http://creativecommons.org/licenses/by/4.0)

INTRODUCTION
Tooth root stress (TRS) is one of the foremost accounts for factors like centrifugal load [3] and web
performance that indices in gear design and research, angle [4] effects at high speeds. Additionally, the
holds significant importance. A high tooth root stress FEM model is versatile in reducing TRS by
can lead to direct gear damage or have an indirect optimizing gear parameters to obtain better
impact on overall gear performance. Accurately and mechanical properties [5]. It is also a valuable tool for
ripidly calculating tooth root stress and deformation evaluating the performance enhancement resulting
serves as a fundamental basis for gear structure from gear tooth profile modifications [6].
design. Currently, there are two primary calculation Furthermore, it can assess the impact of tooth profile
models in use: the FEM model and the analytical variations, machining errors, and assembly errors on
model. TRS using a three-dimensional FEM model [7]. High
The FEM model is a widely adopted approach for contact ratio gears present a specific challenge, as
obtaining accurate and direct measurements of stress their load sharing and deformation between teeth
in the base of gear tooth and deflection. It calculates significantly affect TRS. The FEM model excels. in
in quantifying the impact of various factors, such as calculating these parameters, a task often difficult to
different gear periods, shapes, and slope deviations, achieve with other models. As a result, the scope of
on TRS [1,2]. Furthermore, the FEM model allows research encompasses both uniform [8] and profile
for the analysis of TRS in gears that cannot be modifications [9] for high contact ratio gears, as well
effectively assessed by other models, such as thin- as their optimization to reduce TRS [10–12]. To
rimmed spur gears with inclined webs. This model improve computational efficiency, new numerical
models have been developed [13].

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This paper analyzed stress on the root of tooth and y gw =
πm
+x g m n tanα
deflection 4

generated in a new method. In this article, the stresses x gc = h ga mn - x g m n - ρf sinα

on the base of the gear tooth and deflection values ρf
were compared with FEM result. The alternative ygc =y gw +x gc tanα+
cosα
combined effect of the pressure angles, the face width  r y 
of gear, the addendum coefficients of variation, and γ g =arctan  g - gc 
 x gc x gc 
Eq: (1)
the corner radii adjusted are determined in the new  
model design using the Taguchi method.  rg 
α gc =acos 
 rga cosα 
A. Gear Parameters and Material  
The gears data are selected from the lathe machine Where, ygw is the half length of the cutter pitch line,
and the mechanical properties of the gear material are mn is the normal module, xg is the addendum
shown in Table I and Table II. The gear tooth profile modification coefficient, xgc, ygc is the center
curve of the new method has used this parameter and locations of edge radius of cutter, rg is the reference
material properties as the profile shape is shown in circle radius, ha is the addendum coefficient, ra is the
figure.1. addendum circle radius, ∅ is the independent variable
TABLE I. Geometric parameters in gear for the curve, edge radius of cutter, and γg -
parameters angle of the envelope point.
Parameters Values
C. Load distribution ratio
Number of teeth pinion, Tp 40 The first point for the pinion tooth is contact at 'g,'
Number of teeth gear, Tg 127 while the second tooth makes contact at 'c.' This
Module, m (mm) 1.25 results in a sharing of the load between these two
Pressure angle, 20 points, as illustrated in Figure 2, where the applied
Addendum factor, ha 1.25 load shares these two gear teeth.
Face width, b (mm) 15
TABLE II. Mechanical properties of gear
materials
Parameters Values
Density of material, kg/m3 7800
Yield stress (MPa) 986
Poisson ratio 0.29
Modulus of elasticity (GPa) 190
Brinell Hardness 311
B. Model of a gear tooth
The section curve equation can be divided into five
parts, including the downward curve, downward Fig 2. Gears contact position
transition curve, upward involute curve, upward
In a similar manner, points 'f' and 'b' move
transition curve, and addendum curve.
simultaneously with points 'e' and 'a.' Subsequently,
'a' becomes disconnected, and the full load initially at
point 'e' is transferred to point 'd' until it reaches point
'c,' where the newly connected teeth come into
contact.
The gear operates with a standard contact ratio,
meaning that when a single pair of teeth is engaged,
that specific pair bears the entire load. However,
when two pairs of teeth are in contact, the transmitted
load is distributed between the teeth in the
Fig 1. Basic cutter of gear tooth connection. This load distribution ratio depends on
The profile equation of the gear tooth is used in both the contact ratio and the stiffness of the teeth at
equation (1) to construct the new model. The section the load point position. The load distribution ratio is
of the gear is symmetric about the xg axis, and the particularly evident at points 'e,' 'd,' and 'C,' as shown
center of the gear is at the coordinate point O. in Figure 2.

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For the cases examined, the load distribution ratios Table IV. Taguchi orthogonal L9 array for
remain quite consistent, hovering around R = 0.35, profile level selection
and approaching R = 0.65 at the extremes of the Pressure Addendum Edge
interval where two pairs of teeth engage. At the very No angle modification radius
limit of the engagement interval for a single pair of (degree) (mm) (mm)
teeth, the load-sharing ratio reaches R = 1 [15]. The 1 19 1.25 0.375
load distribution ratio can be expressed as follows: 2 19 1.30 0.500
3 19 1.38 0.625
4 20 1.25 0.625
5 20 1.30 0.375
Eq: (2) 6 20 1.38 0.500
7 21 1.25 0.500
8 21 1.30 0.625
9 21 1.38 0.375
D. Taguchi Method E. Analytical method of the TRS and deflection
Table.III outlines the chosen gear parameter levels, The highest TRS occurs in the transition curve region
while it shows the orthogonal arrangement of L9. In during single tooth contact, which is in line with the
this section, the gear profile is modified with respect gear's working principle. In single-tooth meshing, the
to four parameters: pressure angle, addendum maximum bending moment typically rises, rather than
modification, edge radius, and face width of the gear in double-tooth meshing. Furthermore, the involute
tooth. However, the face width remains constant. curve region near the root is smaller bending moment
Pressure angles are adjusted, and addendum but transition curve region is larger bending moment.
modifications vary between 1.25, 1.30, and 1.38, with The new method introduced in this paper is based on
edge radii of fillet at 0.375 mm, 0.5 mm, and 0.625 these considerations. Figure 3 shows the parameters
mm. of the TRS and deflection calculation method.
Following the involute gear meshing rule, the
TABLE III. Level Selection of the process
direction of the base circle's outer tangent line at the
parameters
meshing point represents the load orientation (F) on
Level the gear. The pressure angle at the meshing point
Profile parameter
1 2 3 (αgF) is the angle between the tangent line and the Yg
Normal pressure angle axis, and it varies at different meshing positions.
19 20 21
(degree) Additionally, ϕgF denotes the value of ϕgiu at the
Addendum modification meshing point. Taking into account the gear's stress
1.25 1.30 1.38
coefficients(mm) characteristics, the standard TRS composed both
Edge radius (mm) 0.375 0.50 0.625 standard bending moment stress and axial
A new method has been developed using the Taguchi compressive stress.
method to consider four different parameter
variations. The Taguchi method utilizes these four
parameters as a simple, effective, and systematic
approach to design optimization, encompassing
performance, quality, and cost considerations. An L9
orthogonal array with 4 columns and 9 rows is
employed to facilitate the process. Initially, the
Taguchi method generates nine distinct simulations,
each utilizing different load distribution ratios and
corresponding positions. The selection of the
minimum contact position is preferred to minimize
applied load[14-15]. Conversely, the maximum
contact position for a single tooth pair may lead to
gear failure, as noise and vibration. Fig 3. Parameters of analytical new model
The tangent line direction of the main circle outside
the mesh point aligns with the load direction (F) on
the gear. The pressure angle at the mesh point (α)
equals the angle between the tangent line and the ygi

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axis, and it varies at different positions. Additionally, F. Analytical Results
ϕg represents the value at the mesh point. The new The load distribution on the gear teeth is determined
model was chosen based on modifications to gear using Eq. (2) at nine different positions.
profile parameters, including adjustments to the
pressure angle, addendum factor, and edge radius,
using the Taguchi method. The pressure angle is
adjusted from 19° to 21°, the addendum modification
is varied from 1.0 to 1.1 times the module, and the
edge radius is changed from 0.3 to 0.5 times the
module. Considering the load characteristics of the
gears, the standard tooth root stress comprises both
standard bending moment and axial stress.
The stress due to bending moment is expressed by
Equation: 3. [5]
3F{[x gu (φ g )-x gt (φ g )]cosα g -y gu (φ g )}×sinα g
σ g =
2 × b × y gt2 (φ g )
Eq:(3)

Where, xg is the addendum modification coefficient, α

Fig 4. Load sharing ratio for all simulations
is the normal pressure angle, xgt, ygt is the center
locations of edge radius of cutter. Figure 2 illustrates the location of the load
distribution ratio from the bottom to the tip of the
The standard axial compressive stress can be
gear tooth. The relationship between the load
expressed by Equation: (4).
distribution along the gear teeth is depicted in Figure
F sinα 4. This paper examines the applied load from the base
σa = Eq:(4)
2×b×y(φg ) to the tip of the gear tooth, considering changes in the
gear tooth profile facilitated by the Taguchi method.
The total standard stresses are obtained by using the
The initial contact points are the same, but the final
Equations: (5) and (6), these equations are based on
contact point differs. Changes in the addendum factor
the base of gear tooth. Total standard compressive
and pressure angle result in variations in contact
stress is achieved as follow:
lengths and contact ratios. Due to these factor
Eq: (5) adjustments, the maximum load-sharing ratio position
is identified at 0.24 mm in Simulation 7, represented
Total standard tensile stress: by the blue color. Conversely, the minimum load-
Eq: (6) sharing ratio position is at 0.07 mm in Simulation 3,
indicated by the red color. Comparing these two
F. Deflection of gear tooth simulations, the maximum load-sharing ratio position
The deflection of gear tooth is calculated by the decreases by 0.17 mm. The position of the maximum
following eq: (7). load distribution ratio slightly decreases in Simulation
3. Therefore, Simulation 3 is chosen among the
A
Deflection, δ= Eq: (7) others. Gear failure occurs at this position as the
B
entire load is applied here. Hence, this position will
In this equation, be reduced to prevent gear surface failure.
The calculation of the maximum tooth root stress
(TRS) and deflection is performed using the results
obtained from the load distribution ratio in all
Where, Ft is the tangential applied load (N), L is the simulations. Tables V. display the contact positions
tooth height, E is the modulus of elasticity (N/mm2), I and the maximum stress due to the applied load along
is the moment of inertial of gear tooth (mm4) the tooth flank in simulations conducted with new
methods.
In this approach the strength is modified by various
factors that produce limiting values of the bending
stress.
Eq: (8)

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TABLE.V. Tooth root stress (using new method) of nodes (or elements) yields a more accurate result,
and contact position. but only up to a certain limit. Consequently, the
point g point e point c Tooth simulation result is governed by the elements and
No to point to point to point root stress nodes, considering the element quantity, aspect ratio,
e c a (MPa) and skewness. The values for elements and nodes in
1 0.80 0.14 0.80 185.84 the FEM method are 1244019 and 292892.
2 0.84 0.10 0.84 185.84
3 0.88 0.07 0.88 185.84
4 0.75 0.20 0.75 185.84
5 0.78 0.16 0.78 185.84
6 0.82 0.12 0.82 185.84
7 0.69 0.24 0.69 185.84
8 0.73 0.21 0.73 185.84
9 0.76 0.18 0.76 185.84
Table V displays the contact position and maximum
tooth root stress using the new method along the gear
tooth. The maximum tooth root stress (185.84 MPa)
occurs when all loads are applied between points 'e'
and 'c.' The minimum contact position is observed in
Simulation 3, making it the position with the smallest
Fig 6. Use the meshing of pinion
gear failure due to the applied load.
Figure 6 displays the mesh of the pinion tooth. The
element quantity for this gear is 0.85652, falling
within the range of 0.7 to 0.95, indicating good
quality. Subsequently, the simulation checks the
aspect ratio, resulting in a value of 1.3809.

Fig 5. Maximum Tooth Root Stress (MPa)

Fig 7. Boundary Condition of Pinion
Figure 5 illustrates the distribution of tooth root stress
An aspect ratio of less than 5 is considered good
at various positions, ranging from the tooth root to the
quality for most elements (90% and above). The
tip, using four different methods. The stresses exhibit
simulation also assesses skewness, with a value of
a gradual increase from the contact position of 0.5
0.19262 falling within the range of 0 to 0.25,
mm to 1.42 mm. The stress sharply decreases from
indicating excellent quality. Skewness is a crucial
1.5 mm to 2.42 mm. The maximum tooth root stress
criterion for mesh quality in a static structure,
is observed when the load is applied at 1.5 mm from
defining the error of cell shape and its equivalent
the base of the gear tooth.Although the value of the
volume. A skewness value closer to one suggests
maximum tooth root stress in the new method is
decreased accuracy.
nearly the same as that in the ISO method, the shape
of the tooth root stress in the ISO method differs from The boundary condition is expressed as a fixed
the other methods. position in the center of the gear, with an applied load
of 1200 N acting on the gear tooth as shown in figure
G. FEM Results
7.
The FEM method employs ANSYS software. The
simulation results indicate that the quality of the mesh Tooth root stress distribution is depicted in Figure 8,
product is influenced by the element quantity, aspect with the highest concentration observed at the base of
ratio, and skewness. Typically, increasing the number the gear tooth.

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stress and deflection of the new method are calculated
with different tooth normal pressure angles,
addendum coefficients, and fillet edges, and are
compared with the FEM method through numerical.
Finally, the results of the new analytical methods are
compared to the FEM method. The new method
utilizes an analytical approach based on mechanics
theory and possesses stronger theoretical properties.
When calculating the maximum tooth root stress
(TRS), both the axial compressive stress and the
bending stress are considered in the new method.
References
Fig 8. Tooth root stress of simulation 3
[1] AGMA Standard 2001-D04, American Gear
Manufactures Association, Alexandria, VA,
2004.
[2] ISO Standard 6336-1,International
Organization for Standardization, Geneva,
Switzerland, 2006.
[3] ISO Standard 6336-2, Calculation of Load
Capacity of Spur and Helical Gears-Part 2:
Calculation of Surface Durability (Pitting),
International Organizattion for Standardization,
Geneva, Switzerland,2006.
[4] ISO Standard 633-6, International Organization
for Standardization,Geneva,Switzerland,2006.
Fig 9. deflection with ANSYS software. [5] T. H. Chong. T. Suzuki. T. Aida. H. Fujio,
Bending Stresses on internal Spur Gears, JSME
The maximum deflection, measuring 0.0097 mm,
Bull. 25(1982) 679-686.
occurs at the tip of the gear tooth and expresses in red
color line. [6] T. H. Chong. A. Kubo. Simple stress formulae
for a thin-rimmed spur gear (Parts 1-3), J.
H. Conclusion
Mech. Trans. Autom. Des. 107 (1985) 406-422.
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