DEPARTMENT OF MECHANICAL ENGINEERING

NATIONAL INSTITUTE OF TECHNOLOGY, ROURKELA

May - 2024

EXPERIMENTAL INVESTIGATION OF
DYNAMIC LOADING ON LOW CONTACT
RATIO(LCR) AND HIGH CONTACT RATIO(HCR)
SPUR GEAR

A THESIS SUBMITTED IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE

DEGREE OF BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING BY

120ME0535 SHREEANSH PRAHARAJ

120ME0277 SUNANDA BHOWMIK
120ME0288 RAHUL PRIYADARSHI KANDAMAKA

UNDER THE GUIDANCE OF

PROF. SUKESH CHANDRA MOHANTY

 NATIONAL INSTITUTE OF TECHNOLOGY
ROURKELA

CERTIFICATE
This is to certify that the thesis entitled, “Experimental Investigation of Dynamic Loading
on Low Contact Ratio(LCR) and High Contact Ratio(HCR) Spur Gear” submitted by
Shreeansh Praharaj, Sunanda Bhowmik, and Rahul Priyadarshi Kandamaka in partial
fulfilment of the requirement for the award of Bachelor of Technology Degree in Mechanical
Engineering at National Institute of Technology Rourkela is a record of original research
work carried out under my supervision.

To the best of my knowledge, the matter embodied in the thesis has not been submitted
to any University/Institute for the award of any Degree or Diploma.

Prof. Sukesh Chandra Mohanty

Date: 13.05.2024 (Supervisor)

Department of Mechanical Engineering
National Institute of Technology,
Rourkela
 ACKNOWLEDGEMENT

We would like to express my sincere gratitude to our project guide, Prof. Sukesh Chandra
Mohanty, for his gracious guidance, unwavering support, and invaluable insights, which
greatly influenced the trajectory of our project.

Our gratitude also goes to our project collaborators and friends for their constant assistance
and contributions, which played a pivotal role in ensuring the timely completion of our
endeavor.

Finally, we express our deep gratitude to our families for their steadfast support and
encouragement throughout our academic pursuits.

Date: 13.05.2024 Shreeansh Praharaj

Sunanda Bhowmik

Rahul Priyadarshi Kandamaka

Department of Mechanical Engineering

National Institute of Technology,

Rourkela
 DECLARATION OF ORIGINALITY
We, Shreeansh Praharaj, Sunanda Bhowmik and Rahul Priyadarshi Kandamaka, hereby
declare that this project entitled “Experimental Investigation of Dynamic Loading on Low
Contact Ratio(LCR) and High Contact Ratio(HCR) Spur Gear” presents our original work
carried out as a Bachelor in Technology student of NIT Rourkela and, to the best of our
knowledge, contains no material previously published or written by another person, nor any
material presented by us for the award of any degree or diploma of NIT Rourkela or any
other institution. Any contribution made to this research by others, with whom we have
worked at NIT Rourkela or elsewhere, is explicitly acknowledged in the project. Works of
other authors cited in this dissertation have been duly acknowledged under the section
“Reference”. We have also submitted our original research records to the scrutiny committee
for evaluation of our dissertation.

We are fully aware that in case of any non-compliance detected in future, the Senate of
NIT Rourkela may withdraw the degree awarded to us based on the present dissertation.

Date: 13.05.2024 Shreeansh Praharaj

Sunanda Bhowmik

Rahul Priyadarshi Kandamaka

Department of Mechanical Engineering

National Institute of Technology,
Rourkela
 CONTENTS
S. No. Title Page No.
i Abstract

ii List of Tables

iii List of Figures

iv Nomenclature

Chapter 1 Introduction 8

Chapter 2 Literature Review 11

Chapter 3 Research Gap 17

Chapter 4 Objective 17

Chapter 5 Methodology 17

5.1 Equipment Required 17

5.2 Design and Assembly 19

5.2.1 Calculations 19

5.2.2 Procurement and Assembly 21

5.2.3 Electrical Component Assembly 22

Chapter 6 References 25
 ABSTRACT

Gears play a crucial role in transmitting power in various fields like automobiles, marine
vessels, and power plants, where they provide mechanical advantage. The strength and
endurance of gears depend on factors like their size and surface hardness. However, their
downside is their weight, which results in increased energy losses.

To address these challenges, engineers are exploring solutions like optimizing gear design
and using high contact ratio gears. These approaches aim to improve the power transmitted
relative to weight and minimize dynamic stresses.

In this study, we investigate the dynamic behavior of gear teeth through practical
experimentation. Gears with a module size of 4.6 mm (resulting in tooth height exceeding
10 mm) are employed. The experimental setup involves subjecting the gear to input from a
3-phase motor and applying a reversing torque using a magnetic brake. Using strain gauges,
we measure the deflection of the gear teeth. The strain gauge data, processed through a
Wheatstone bridge, is then analyzed via an oscilloscope to approximate the contact stresses.
This experiment is conducted across various speeds to observe how gear dynamics vary with
speed changes.

Keywords: Gears, Module, Dynamic Behavior, Contact Stresses, Strain Gauges, High
Contact Ratio Gears, Oscilloscope.
 List of Tables
Sl No. Table No. Title Page no.
1 5.1 Components of experimental setup 18

2 5.2 Gear Dimensions 19

3 5.3 Shaft Properties and bending deflection 20

List of Figures
Sl. No. Fig. No. Title Page No.
1 5.1 Front View of Mechanical components Assembly 21

2 5.2 Circuit Diagram of Wheatstone Bridge 22

3 5.3 Controller Circuit 23

4 5.4 Strain Gauge connected to copper discs (rotating 23

inside acrylic sheets)

5 5.5 Strain Gauge and Potentiometers connected in 24

Wheatstone Bridge Circuit

6 5.6 Complete Setup Assembly 24

7 5.7 Complete Setup Top View 25

1. Introduction
Gears serve as essential components in machines, enabling the smooth transfer of power and
movement between rotating shafts. These systems consist of toothed wheels or cylinders that mesh
together, ensuring torque and rotation transfer at specific speed ratios. At the heart of gear
mechanisms are the gear wheel and pinion, the larger and smaller gears, respectively, that interlock
to transmit torque between shafts. Precision engineering ensures the teeth of gears fit seamlessly,
resisting slippage or breakage under load. Various gear types exist, including spur, helical, bevel,
and worm gears. Spur gears, the simplest type, feature cylindrical wheels with teeth along their
edges. Helical gears boast slanted teeth for enhanced efficiency and load-bearing capacity. Bevel
gears facilitate power transmission at oblique angles, often redirecting rotational motion.
Meanwhile, worm gears, with their helical shape, excel at perpendicular power transmission. Gears
find applications across a spectrum of mechanical systems, from basic hand tools to complex
machinery. Their significance extends to automotive transmissions, industrial equipment, and
robotics, where they play a crucial role in power transmission and motion control.

Shafts play a vital role in transferring rotational force and movement between rotating components.
These cylindrical or tapered rods offer support and enable the transmission of power from motors
or engines to various mechanical parts like gears, pulleys, or couplings. Their key function is to
transfer torque while maintaining alignment and minimizing deflection. Typically crafted from
robust and high strength materials like steel, mild steel, stainless steel, or titanium, shafts are
designed to withstand the stresses and loads of their intended applications. They come in different
types, each serving specific purposes. The most basic type of shafts are straight shafts, which has
a consistent diameter throughout, are suitable for low speed, low torque conditions. Stepped shafts
feature varying diameters along their length, adjusting rotational force and velocity as needed.
Splined shafts boast ridges and grooves to interlock with other components, facilitating torque
transfer. Tapered shafts, conically shaped, excel at transmitting torque between closely fitting
elements like bearings. Shafts are integral components in numerous mechanical systems, including
automotive engines, industrial machinery, and aircraft. Enduring high levels of stress and weight,
they undergo rapid rotation and oscillation. The efficiency and reliability of these systems hinge
on the careful selection and maintenance of shafts.

A coupling serves as a crucial link between two shafts, enabling the transmission of rotation and
torque while allowing for some degree of shaft misalignment. Couplings come in various types,
each designed with a specific structure and purpose to meet diverse needs. Among the common
categories are jaw couplings, known for their simplicity and affordability in connecting shafts
through curved jaws. Gear couplings are favored for applications demanding high torque, featuring
hubs with external teeth that mesh together. Disc couplings find use in high-speed settings,
connecting hubs via thin metal discs. Flexible couplings, made from materials like rubber,
elastomers, or metals, are employed to rectify misalignment between shafts. Selecting the right
coupling is critical as they play vital roles in mechanical systems. Couplings must withstand the
forces and strains inherent in the system while accommodating any potential shaft deviations. The
effective and dependable performance of mechanical systems hinges on the careful selection and
upkeep of couplings.

Bearings play a vital role in facilitating the movement of rotating shafts and other mobile
components by providing essential support. Lubrication plays a crucial role in reducing friction
and wear by creating a smooth interface between moving parts, ensuring seamless motion. There's
a wide variety of bearings, each designed for specific purposes. For instance, ball bearings,
consisting of steel balls within a raceway, are versatile and used to support both radial and axial
loads across various industries like automotive and industrial machinery. Roller bearings, on the
other hand, employ cylindrical or tapered rollers and are ideal for handling heavier loads,
commonly found in large machinery and equipment. Plain bearings, the simplest type, feature two
surfaces gliding against each other to reduce friction and provide support, often used in low-speed
and low-weight situations. Thrust bearings specialize in handling axial loads and find application
where significant thrust is involved. Choosing the right bearing is crucial as they are integral to
mechanical systems. They must provide a low-friction interface to withstand the loads and strains
of the system. The efficient and dependable operation of mechanical systems relies on the careful
selection and maintenance of bearings.

The magnetic brake serves as a mechanism to slow down or stop rotating components, like motors
or rotors, by utilizing magnetic fields. It consists of two main parts: the stationary stator, which
generates the magnetic field, and the rotating rotor, which responds to this field with either
attraction or repulsion. When the magnetic field is applied, the rotor experiences a braking force,
causing it to decelerate. The strength of this force can be adjusted by changing the magnetic field's
intensity, allowing for precise control over the rotational speed and stopping of the component. In
industrial settings, magnetic braking systems are commonly used to accurately regulate the speed
of rotating machinery. They find applications in printing presses, machine tools, and other
equipment requiring precise stopping and positioning. Compared to traditional friction-based
brakes, magnetic brakes offer several advantages such as longer lifespan, increased accuracy, and
reduced maintenance requirements.

The strain gauge serves as a sensitive sensor used to detect and measure the deformation or strain
experienced by an object, converting it into an electrical signal. This device typically consists of a
thin, flexible wire or metal leaf attached to the surface of the object being studied. When the object
deforms due to applied force or load, the strain gauge also deforms, leading to a change in its
electrical resistance. This change in resistance is directly correlated with the amount of strain and
can be measured using techniques like the Wheatstone bridge circuit. Strain gauges find
widespread use across various fields such as mechanical engineering, civil engineering, and
aerospace to quantify stresses and strains in structures and materials. They offer precise and
accurate real-time measurements of deformation and are often combined with other sensors to gain
a comprehensive understanding of how a system or structure behaves under different loading
conditions.

The oscilloscope is a valuable tool in laboratories, used to observe and interpret voltage signals as
they change over time. It takes electrical signals and converts them into visual waveforms
displayed on a screen, allowing users to analyze properties like amplitude, frequency, and timing.
These waveforms typically appear as lines moving across the screen, with the grid representing
time and voltage. Oscilloscopes have applications across various fields such as electronics,
telecommunications, engineering, and physics. They serve as a diagnostic aid for troubleshooting
electrical circuits and equipment. Modern digital oscilloscopes are equipped with advanced
features like automatic measurements, waveform storage and recall, and sophisticated analysis and
signal processing capabilities.

Acrylic sheets, known for their versatility and durability, play a crucial role as grooves in various
applications. These sheets, made from polymethyl methacrylate (PMMA), offer a transparent and
lightweight alternative to glass, making them popular in industries ranging from construction to
signage. From architectural designs to artistic installations, acrylic sheets serve as functional and
aesthetic elements, enhancing both form and function. Various unique properties of acrylic sheets
that make them ideal for grooving applications, such as their resistance to impact, weathering, and
UV radiation.

The Variac, also known as an auto-transformer or variable transformer, serves as an electrical

device allowing for flexible adjustment of output voltage. It consists of a single wire coil wound
around a toroidal core, alongside a movable brush for contacting different points on the coil. By
adjusting the brush's position, users can regulate the output voltage to meet specific requirements.
Variacs find widespread use in industrial and laboratory settings, providing variable AC voltage
crucial for tasks like equipment testing, calibration, and controlling AC motor speeds. In audio
equipment, voltage regulators play a vital role in modulating input voltage, ensuring smooth and
uninterrupted adjustment of output voltage. Variacs offer several advantages over other
transformer types, including their ability to handle high currents and provide precise and
continuous adjustment of output voltage.

2. Literature Review
Simulating and validating the dynamic contact of gear teeth is a crucial stage in the design and
analysis of involute spur gears. Liu Y.et al.[1] introduced a dynamic gear model utilizing the
Adams Subroutine secondary development platform, which integrates tooth contact and multi
tooth contact modules. This approach combines computational simulations with empirical
experiments to investigate gear tooth contact mechanics under various operating conditions.
Experimental tests on physical gear systems validate the results of tooth dynamic contact
simulations, typically involving measurements of tooth deflection, contact pressure, and other
significant parameters using sensors like strain gauges and pressure transducers. Comparing actual
outcomes with simulated results verifies the accuracy of the simulation. By employing tooth
dynamic contact simulation and experimental validation methods, designers can optimize gear
systems by refining gear tooth geometry. Simulation results help identify areas with high stress
concentration, allowing designers to improve tooth profiles to reduce stress levels. Following
optimization, experimental validation ensures the practicality of the design and confirms that the
gear system meets performance criteria.

Tamminana VK.et al.[2] developed two dynamic models, a finite element based deformable body
model and a simplified discrete model, to predict the dynamic performance of spur gear pairs.
Their study involves calculating dynamic transmission error (DTE) and dynamic factors (DF) for
various unmodified and modified spur gears, based on gear mesh loads, tooth loads, and bending
stresses. The analysis spans a wide range of rotational speeds, involute contact ratios, and torque
values. Their research focuses on validating these models using experimental data from tests on
both unaltered and altered tooth profiles of spur gears. Additionally, the study aims to establish a
direct relationship between dynamic transmission error (DTE) and various manifestations of
dynamic factors (DF), particularly those based on tooth forces and root stresses. The study also
evaluates the impact of nonlinear behavior, such as tooth separations and jump discontinuities, on
DF. This research provides simplified mathematical expressions to express the relationship
between expected DF and DTE values, aiding in the understanding of gear dynamics.

The shape and dimensions of gear teeth can change over time due to various factors like varying
loads, debris, friction-induced overheating, wear, and backlash. Ambaye G.et al.[3] investigated
how backlash or uniformly worn-out tooth faces affect the dynamics of spur gears, particularly
focusing on gear contact and angular accelerations. They studied the impact of uniformly
distributed worn-out surfaces on gear tooth dynamics, modeling it as backlash. The study varied
gear tooth backlash from 0 mm to 1 mm in increments of 0.2 mm and analyzed gear performance
under multiple loading conditions using MSC ADAMS software. This research sheds light on how
changes in gear tooth profile, such as backlash or worn-out surfaces, influence gear dynamics,
providing valuable insights for understanding and optimizing gear performance in real-world
applications.

Özgüven HN.[4] developed a comprehensive model with six degrees of freedom to analyze the
dynamics of spur gears, considering non-linearity and semi-definiteness. This model incorporates
time-varying mesh stiffness and includes a pair of spur gears, two shafts, inertias representing load
and prime mover, and bearings. By accounting for both shaft and bearing dynamics, the model
enables the analysis of lateral-torsional vibration coupling effects on gear dynamics. The non-
linear model encompasses various factors such as time-varying mesh stiffness and damping, tooth
separation, backlash, single- and double-sided impacts, as well as different gear errors and profile
modifications. This research provides a thorough understanding of the complex dynamics involved
in spur gear systems, offering valuable insights for optimizing gear performance and minimizing
vibration-induced issues in practical applications.

Lin H. et al.[5] investigated how linear and parabolic modifications to tooth profiles impact the
dynamic loading of spur gears. These modifications aim to improve load distribution and minimize
dynamic stresses within the gear system. Using ANSYS software, they developed a finite element
model of the gear system, followed by dynamic analysis using the harmonic balance method. Their
findings reveal that incorporating linear and parabolic profile modifications effectively reduces
dynamic tooth stresses and improves load distribution in the gear system. Their study shows that
the parabolic modification demonstrates greater efficacy in reducing dynamic stresses compared
to the linear modification. This research highlights the potential of profile modifications in
optimizing gear performance and mitigating dynamic loading issues, offering valuable insights for
gear design and engineering practices.

Li C. et al.[6] conducted a dynamic simulation analysis of a space-driven spur gear system under
a substantial inertia load. They utilized ADAMS software to construct the simulation model and
examined how different design parameters affect the system's dynamic response. Their
investigation revealed that the presence of an inertia load significantly influences the dynamic
characteristics of the gear system. As the inertia load increases, gear tooth contact forces, dynamic
gearbox error, and vibration levels also increase. However, they found that increasing the gear
module and tooth count can improve the system's load-bearing capacity and reduce its dynamic
response. Overall, the study emphasizes the importance of considering inertia loads in the design
and optimization of spur gear space-driven mechanisms. The insights gained from the simulation
analysis provide valuable guidance for enhancing the performance of such systems under large
inertia loads.

Alemayehu FM. and Ekwaro-Osire S.[7] delved into the effects of uncertainty on the dynamic
loading and failure of spur gear pairs. Their study explored various sources of uncertainty, such as
manufacturing tolerances, material properties, and operating conditions, aiming to understand their
impact on gear tooth stresses and the risk of gear failure. They employed ANSYS software to
develop a finite element model of the gear system and conducted a probabilistic analysis using
Monte Carlo simulation. Their findings revealed that variations in gear tooth geometry and
material properties significantly affect gear tooth stresses and the likelihood of gear failure. The
study suggests that increasing the safety factor or improving manufacturing and inspection
procedures can reduce the risk of gear failure. Overall, the research contributes valuable insights
to optimizing and evaluating spur gear pairs, potentially enhancing their effectiveness and
reliability under unpredictable circumstances.

Furch J. et al.[8] utilized MSC Adams software to simulate the failure of a gearbox with the aim
of understanding the root causes and identifying key factors leading to this failure. Their
investigation involved developing a dynamic model of the gearbox using MSC Adams software,
followed by a series of simulations to analyze gear tooth stresses, dynamic gearbox error, and
vibration levels. Their findings revealed that the gearbox failure was attributed to increased wear
and fatigue of the gear teeth, resulting from elevated contact stresses and cyclic loading. They
identified gear teeth and bearings as the primary contributors to the malfunction. Overall, the
research offers valuable insights into gearbox development and maintenance, potentially
improving their efficiency and reliability. By understanding the factors contributing to gearbox
failure, manufacturers and engineers can take proactive measures to enhance gearbox performance
and longevity.

Andhare AB. et al.[9] conducted a study focusing on detecting profile inaccuracies in spur gear
pairs. They developed a mathematical framework to simulate the dynamic forces generated when
gears with profile inaccuracies mesh together. The model considers factors like the geometric
characteristics of gear teeth, applied forces' direction and magnitude, as well as gears' speed and
torque. The simulation results revealed significant changes in dynamic forces due to profile errors
during gear meshing. These modifications help in identifying profile inaccuracies and measuring
their extent. The research suggests that the proposed simulation model can be a valuable tool for
detecting profile inaccuracies in spur gear pairs, thereby aiding in improving gear design and
manufacturing processes.

Dewanji P.[10] conducted an investigation to assess the design and analysis of spur gears. This
research involved developing the gear tooth profile, evaluating gear tooth stress, and determining
gear parameters such as gear module, number of teeth, and center distance. The gear was modeled
in 3D using SolidWorks software and underwent finite element analysis(FEA) using ANSYS
Software. The findings revealed that the stresses experienced by the gear tooth were well below
the material's yield strength, indicating that the gear design met the prescribed load capacity and
service life criteria. The study highlighted the significant influence of both gear tooth profile and
gear parameters on gear tooth stresses and performance. Overall, the research emphasized the
importance of carefully examining gear tooth profile and gear parameters in spur gear design and
analysis. The utilization of 3D computer-aided design (CAD) modeling and finite element analysis
(FEA) was found to be beneficial in enhancing gear design and determining necessary gear
parameters. The study underscored the importance of considering material characteristics,
operating conditions, and manufacturing tolerances during the gear design and analysis process.

Vinayak H. et al.[11] conducted an analysis of the linear dynamic properties of multi mesh
transmissions featuring externally mounted, rigid gears. Their research aimed to understand how
these transmission systems respond to varying loads and operational conditions and to assess the
influence of gear mesh stiffness and damping on vibration levels and dynamic transmission error.
They utilized a lumped parameter approach to create a mathematical model of the transmission
system and conducted time domain simulations using MATLAB. The findings highlighted the
significant impact of gear mesh stiffness and damping on the dynamic characteristics of the
gearbox system, potentially leading to increased vibration levels and dynamic gearbox error. Their
study suggests that optimizing gear mesh stiffness and damping, along with the use of appropriate
damping components like oil film bearings, can help minimize vibration levels and dynamic
transmission error. The research underscores the importance of considering stiffness and damping
in gear mesh design to improve gearbox system performance. Overall, their approach using lumped
parameter modeling and MATLAB simulations provides an effective method for analyzing the
linear dynamic behavior of multi mesh transmissions with externally mounted, rigid gears.

Marques P. et al.[12] introduced a new gear design concept featuring constant mesh stiffness by
developing an analytical model for load sharing and mesh stiffness in various gear types. Their
research aimed to analyze how gear teeth distribute loads and interact under different operational
conditions, and to assess the effects of gear profile modifications on load sharing and mesh
stiffness. Their study involved creating an analytical model by integrating tooth contact analysis
and finite element analysis, which was validated through experimental testing. The results
demonstrated that optimizing gear profile modifications can enhance load sharing and mesh
stiffness, allowing for the achievement of a constant mesh stiffness gear design by carefully
selecting profile modification parameters. Overall, their findings suggest that the analytical model
serves as an effective tool for designing and analyzing gear systems, offering insights into
improving gear performance and reliability. This research contributes to advancements in gear
design methodologies and highlights the importance of considering gear profile modifications for
optimizing gear system performance.

Guerine A. et al.[13] studied the dynamic behavior of a spur gear system affected by uncertain
friction coefficients. Their study aimed to understand how the gear system responds under
conditions of uncertain friction coefficients and to assess its sensitivity to changes in this
parameter. Using a lumped-parameter approach, they constructed a mathematical model of the
gear system and conducted time-domain simulations using MATLAB. Their findings revealed that
the gear system displayed a high sensitivity to fluctuations in the friction coefficient, leading to
significant changes in its dynamic response, including vibration levels and dynamic gearbox error.
The research emphasized the importance of optimizing design parameters such as mesh stiffness
and damping, as well as implementing appropriate lubrication and surface treatments, to minimize
variations in the friction coefficient. These results underscored the need to account for friction
coefficient variability in the development and evaluation of gear mechanisms, highlighting its
impact on system performance and reliability.

Li B. et al.[14] investigated the dynamic performance of involute gear systems using simulation
software ADAMS/Engine. Their study focused on evaluating how variations in gear parameters
such as mesh stiffness, damping, and tooth profile modifications impact the dynamic behavior of
the gear system. They developed a mathematical model of the gear system using lumped-parameter
methodology and conducted time-domain simulations with ADAMS/Engine. The results revealed
that changes in gear parameters significantly affected the gear system's dynamic response,
highlighting the importance of parameter optimization for improved system performance and
reduced vibration levels. The research emphasized the effectiveness of ADAMS/Engine
simulation software for designing and evaluating gear systems, emphasizing the need to consider
dynamic behavior during the design and analysis phase. Their findings underscored the importance
of meticulous parameter optimization to enhance gear system effectiveness and minimize vibration
levels, offering valuable insights for gear system design and optimization.

Li X. et al.[15] conducted a scholarly investigation focusing on the dynamic behavior of involute

gear systems using ADAMS/Engine simulation software. Their study aimed to analyze how
variations in gear parameters, such as mesh stiffness, damping, and tooth profile modifications,
impact the dynamic response of the gear mechanism. They developed a mathematical model of
the gear system using the lumped-parameter methodology and performed time-domain simulations
with ADAMS/Engine. Their findings revealed that changes in gear parameters had a significant
impact on the gear system's dynamic response, highlighting the importance of parameter
optimization for improving performance and reducing vibration levels. The research emphasized
the need to consider the dynamic characteristics of gear systems during the design and analysis
phase, showcasing the effectiveness of ADAMS/Engine simulation software for this purpose.
Their findings underscored the importance of carefully optimizing gear parameters to enhance
system efficiency and minimize vibration levels, offering valuable insights for gear system design
and optimization.

3. Research Gap
As mentioned in earlier papers, it has been highlighted that low contact ratio gears tend to
experience considerably higher dynamic stresses compared to high contact ratio gears. However,
none of these studies provide experimental setups or procedures to validate this theory.
Additionally, none of the papers delve into the behavior of gear teeth when the input speed
undergoes variations and the resulting changes. Therefore, conducting experimental research to
explore the dynamic behavior of gear teeth under varying loads would be highly beneficial to
address these gaps in the existing literature.

4. Objective
• To analyze the experimental results of dynamic loading of the gear teeth.

• To determine the optimal contact ratio for enhanced dynamic performance (minimizing
contact stress).

• To examine the results corresponding to the instantaneous load variations.

5. Methodology
The below given experimental methodology was followed, in this research work, which includes
various steps such as procurement and assembly, experimentation, strain deformation calculation
etc. which are discussed in the following pages.

5.1. Equipment Required

The following components were required in this experimental setup:
Table 5.1- Components of Experimental Setup

S. No. Components Description

Module: 4.6
1 Spur Gear- 1 (Driver gear) No. of teeth: 43
Material: Chromoly Steel
Module: 4.6
2 Spur Gear- 2 (Driven gear) No. of teeth: 43
Material: Chromoly Steel

Diameter: 35mm
3 Input shaft Length: 460mm
Material: Mild Steel
Stepped shaft
Diameter: 35mm and 18mm
4 Output shaft
Length: (390+70)mm
Material: Mild Steel

Circular discs
5 Copper discs (4 Nos.) Diameter: 6” or 152.4mm
Bore diameter: 39mm
Thickness: 2.5mm
6 Flange coupling Bore diameter: 18mm
Company: Powerdrive
7 Self-aligning bearings Standard: UCP-207
Bore diameter: 35+-0.05mm
8 2 pulleys and V-belt -
9 Motor controller Rated
10 Magnetic brake -
11 3-Phase AC source -
12 Oscilloscope -
13 Strain gauge Gauge Factor: 1.98
14 Potentiometer (3 Nos.) 115 Ω each
15 3-Phase AC Motor Rated
5.2. Design and Assembly
5.2.1 Calculation
Initially, the dimensions of the gears were determined using Standard Gear profile formulas, with
a module of 4.6mm and 43 teeth in each gear. Following the computation of the fundamental gear
dimensions, we proceeded to calculate the length of action, base pitch, and contact ratio utilizing
the following formulas:

2 2 2 2
𝑟 −𝑟 + 𝑟𝑎𝑔−𝑟𝑏𝑔−𝑐sin𝑠𝑖𝑛 ∅
𝑎𝑝 𝑏𝑝 𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝐴𝑐𝑡𝑖𝑜𝑛
𝐶𝑅 = 𝑝𝑏
= 𝐵𝑎𝑠𝑒 𝑃𝑖𝑡𝑐ℎ

π*𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑏𝑎𝑠𝑒 𝑐𝑖𝑟𝑐𝑙𝑒 𝑜𝑓 𝑔𝑒𝑎𝑟

Where 𝑝 =
𝑏 𝑛𝑜. 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ 𝑜𝑓 𝑔𝑒𝑎𝑟

2
𝐿 = [ 𝑎𝑑𝑑𝑒𝑛𝑑𝑢𝑚 𝑟𝑎𝑑𝑖𝑖 𝑜𝑓 𝑝𝑖𝑛𝑖𝑜𝑛 2− 𝑏𝑎𝑠𝑒 𝑐𝑖𝑟𝑐𝑙𝑒 𝑟𝑎𝑑𝑑𝑖 𝑜𝑓 𝑝𝑖𝑛𝑖𝑜𝑛 2
+ 𝑎𝑑𝑑𝑒𝑛𝑑𝑢𝑚 𝑟𝑎𝑑𝑖𝑖 𝑜𝑓 𝑔𝑒𝑎𝑟 − 𝑏𝑎𝑠𝑒 𝑐𝑖𝑟𝑐
𝑎𝑐

Where phi(ɸ) is pressure angle

Therefore, after calculating the dimensions of the gear the values were as follows:
Table 5.2- Gear Dimensions

Parameters Symbol Drivers (1) Driven (2)

No of Teeth z 43 43

Pressure Angle α 20 degrees

Module m 4.75

Base circle Diameter Db 191.93 mm 191.93 mm

Face width b 23.75 mm

Root Diameter Dd 192.85 mm 192.85 mm

(Dedendum Diameter)

Form Diameter Df 194.75 mm 194.75 mm

 Outer Diameter Da 213.75 mm 213.75 mm
(Addendum Diameter)

Pitch circle thickness - 7.125 mm 7.125 mm

Pitch Circle Diameter D 204.25 mm 204.25 mm

Base pitch pb 14.02 mm

Pitch p 14.92 mm

Centre to Centre distance C 204.25 mm

Length of action Lac 23.59 mm

Backlash k 0.673 mm

Contact Ratio CR 1.68

These gears were available in the lab itself along with the shafts, whose dimensions are calculated
using the torsion equation and deflecting gravity. The shafts are considered as simply supported
beams with bearings acting as the support for the system.

Therefore, after the torsion equation and the bending analysis the calculated diameter of the shaft
amounted to approximately 33 mm. However, due to bearing standard restrictions, the shaft
diameter was increased to 35 mm.

So the corresponding shaft bending is as follows:

Table: 5.3- Shaft Properties and bending deflections

Sl No. Properties Value

1 Diameter 35 mm

2 Material Mild Steel

3 Weight of the shaft 11.78 kg

4 Bending due to point load 0.0053 mm

5 Bending due to uniformly distributed load 0.0061mm

 6 Total bending 0.012 mm

So the total bending deflection was found to be 0.012 mm.

5.2.2 Procurement and Assembly

The gears, bearings, pulleys, and the couplings were available in the lab itself which were
according to the above required design characteristics. The gears and shafts were assembled along
with the magnetic brake and the motor. The magnetic brake and the motor were bolted to the base
to provide support and dampen the vibration caused. The circular copper discs were manufactured
according to the required diameter, as mentioned above. A smaller hole was cut into the discs same
as the shaft diameter. The acrylic sheets were cut into required shape and slots were made into
them in which the copper discs would rotate. Two small holes were created into the acrylic sheets
for electrical connection. The copper discs were bolted to PVC flanges which were inserted on one
of the shafts. The acrylic sheets were kept on a wooden plank which acts as the base plate and is
tied to the whole structure. Two V-belts were used to connect the pulley to the input motor.

Figure 5.1: Front View of Mechanical components Assembly

5.2.3 Electrical Components Assembly
After the assembly of the mechanical components, the electrical connections were made. The
electrical components of the systems were motor controller, a strain gauge, 3 potentiometers,
voltage source, oscilloscope, 3-Phase source and conductors. Once the mechanical connection was
completed, a strain gauge was connected to one tooth of the gear after cleaning it using sandpaper,
and two ends of this gauge were soldered to two conducting wires which were then connected to
the two copper discs. Two more connecting wires were passed through the acrylic sheet via iron
powder-acetone mixture which acts as a conducting medium. These wires were connected to the
three potentiometers which were set to a resistance of 115Ω each forming a Wheatstone Bridge
circuit. The strain gauge was considered as R1 and the three potentiometers were considered as
R2, R3, and R4. The voltage source was connected across R1-R2 and R3-R4 which supplied 6V.
The oscilloscope was connected across R1-R3 and R2-R4. The circuit diagram of the Wheatstone
Bridge is shown below.

Figure 5.2: Circuit Diagram of Wheatstone Bridge

 Figure 5.3: Controller Circuit

Figure 5.4: Strain Gauge connected to copper discs (rotating inside acrylic sheets)
 R1

R4

R3

R2
Figure 5.5: Strain Gauge and Potentiometers connected in Wheatstone Bridge Circuit

Figure 5.6: Complete Setup Assembly

 Figure 5.7: Complete Setup Top View

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