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M. Harika Chowdary* et al.
(IJITR) INTERNATIONAL JOURNAL OF INNOVATIVE TECHNOLOGY AND RESEARCH
Volume No.4, Issue No.6, October – November 2016, 5051-5054.
Design Modelling And Finite Element
Analysis Of Double Helical Gearing System
For High Speed Compressor Engines
M.HARIKA CHOWDARY G. RAJESWARA RAO
Research Scholar Assistant professor
Department of Mechanical Engineering Department of Mechanical Engineering
St.Marys College of Engineering St.Marys College of Engineering
Guntur, India. Guntur, India.
K.MOHAN KUMAR M.GOPI KRISHNA
Assistant professor Assistant professor
Department of Mechanical Engineering Department of Mechanical Engineering
St.Marys College of Engineering Acharya Nagarjuna University.
Guntur, India.
Abstract: High speed gears are designed to transmit power through parallel or, less commonly,
perpendicular axes. The unique tooth structure of a gears consists of two adjacent, opposite helixes that
appear in the shape of the letter 'V'. Helical gears with multiple teeth on both sides are engaged during
rotation, distributing the work load and offering quiet operation. However, due to their tooth structure,
double helical gears nullify the axial thrust typical of helical gears. The gear set's teeth may be
manufactured so that tooth-tip aligns with the opposite tooth-tip, or so tooth-tip aligns with the opposite
gear's tooth trough. In this project, high speed gears are used in a compressor gear box will be designed
and modeled in 3D modeling software CATIA. Static analysis, Modal analysis and Fatigue analysis will
be done on the gears in Ansys. Different materials are analyzed for comparison Structural Steel, Cast
Iron and Alloy Steel. The better material is determined from this analysis.
Keywords: Helical Gears; 3D Modeling Software CATIA;
I. INTRODUCTION II. PROBLEM DEFINITION
The term “Gear” is defined as a machine element The objective of this project is to make a 3D model
used to transmit motion and power between of the helical gears used in a compressor gear box,
rotating shafts by means of progressive rendezvous is designed and modeled in 3D modeling software
of projections called teeth. Invention of the gear Solid works and Catia. Static analysis, Modal
cannot be attributed to one individual as the analysis and Fatigue analysis is done in Ansys.
development of the toothed gearing system evolved
III. METHODOLOGY
gradually from the primitive form when wooden
pins were arranged on the periphery of simple, solid, A 3D model of the gear using solid- works
wooden wheels to drive the opposite member of the software is generated and imported to ANSYS to
pair. These wheels served the purpose of gears in Perform Static analysis on the gear. Modal analysis
those days. Gears are used in most types of is Performed on the gear, Different materials are
machinery. Like nuts and bolts, they are common analyzed for comparison of Cast Steel, Cast Iron,
machine elements that will be needed from time to structural steel, Based on the results obtained, some
time by almost all machine designers. Gears have design changes are implemented to get better
been in use for over many years, and they are an material for gear.
important element in all machinery used now days.
IV. LITERATURE REVEIEW
Type of gears
Negash Alemu, 2007.This thesis investigates the
There is a wide Variety of types of gears in characteristics of an involute helical gear system
existence, each serving a range of functions. In mainly focused on bending and contact stresses
order to understand gearing, it is desirable to using analytical and finite element analysis. To
classify the more important types in some way. estimate the bending stress. From the results of this
One approach is by the relationship of the shaft study, the following specific conclusions are
axes on which the gears are mounted. As listed in drawn: The strength of the gear tooth is a crucial
Table, shafts parallel. Intersecting or non parameter to prevent failure. It is also shown that
intersecting and non parallel. the development of finite element analysis model
of the equivalent contact cylinders to simulate the
contact stress between two gears reasonably .Based
2320 –5547 @ 2013-2016 http://www.ijitr.com All rights Reserved. Page | 5051
M. Harika Chowdary* et al.
(IJITR) INTERNATIONAL JOURNAL OF INNOVATIVE TECHNOLOGY AND RESEARCH
Volume No.4, Issue No.6, October – November 2016, 5051-5054.
on the result from the contact stress analysis the analysis and Finite Element Analysis are compared
hardness of the gear tooth profile can be improved to check the correctness. Results indicate that:
to resist pitting failure The face width and helix Bending, compressive, Von-misses stresses were
angle are an important geometrical parameters obtained by theoretical and Ansys software for
during the design As it is expected, in this work the Aluminum alloy. The obtained stresses by ANSYS
maximum bending stress decreases with increasing are less than that of the theoretical calculations.
face width and it will be higher on gear of lower From the results, it is observed that the bending and
face width with higher helix angle. compressive stresses of aluminum alloy (ceramics)
are less than that of the other material like steel.
Aarthy Vaidyanathan,, 2009.In this study, a test
Aluminum alloy reduces the weight up to 5567%
methodology for measuring load-dependent
compares to the other materials .Aluminum is
(mechanical) and load independent power losses of
having unique property (i.e. corrosive resistance),
helical gear pairs is developed. A high-speed four-
good surface finishing, hence it permits excellent
square type test machine is adapted for this
silent operation. Weight reduction is a very
purpose. Several sets of helical gears having
important criterion, in order to minimize the UN
varying module, pressure angle and helix angle are
balanced forces setup in the marine gear system,
procured, and their power losses under jet
there by improves the system performance. Hence
lubricated conditions are measured at various speed
aluminum alloy is best suited for marine gear in the
and torque levels. The following conclusions can
high speed applications The designed gear set have
be made based on the experimental study: The gear
been manufactured using gear hobbing technique
module and pressure angle are more significant
and finished by gear shaving operation and tested
than the helix angle in terms of their influence on
for the strength of the gear teeth.
gearbox power losses. Similar to the findings of
Petry-Johnson and Moorhead , the gearbox V. AIM OF THE PROJECT
mechanical power loss increases almost linearly
Optimal design of gears requires the consideration
with rotational speed and shows an increase beyond
of the two type parameters: Material and
a linear relationship with input torque. The
geometrical parameters. The choice of stronger
measured spin power loss values for every gear set
material parameters may allow the choice of finer
tested were very close to each other, suggesting
geometrical parameters and vice versa. Very
that gear parameters varied are not critical to spin
important difference among these two parameters is
losses, confirming results of Seetharaman and
that the geometrical parameters are often varied
Kahraman .
independently. On the other hand, material
Raghava Krishna Sameer, V.Srikanth,2014. parameters can be inherently correlated to each
other and may not be varied independently. Because
This study presents a One of the main reason of
of widely varying requirements, gears are produced
the failure in the gear is bending stresses and
from a wide variety of materials. These materials
vibrations also to be taken into account. But the
include plastics such as nylon, powdered metals,
stresses are occurred due to the contact between
brasses, bronzes, cast or ductile irons, and steels.
two gears while power transmission process is
Many types of steels, including stainless steel and
started. Due to meshing between two gears contact
tool steel, are used.
stresses are evolved. The strength of the gear tooth
is important parameter to resist failure. In this The thrust forces impose reactions on the bearings.
study, it is shown that the effective method to This increases the size and cost of bearings. The
estimate the contact stresses using three thrust forces on input and output shafts can be
dimensional model of both the different gears and eliminated by using herringbone or double helical
to verify the accuracy of this method. Can be gears.
improved to resist pitting failure a phenomena in
The main aim of this project is to optimize the
which a small particle are removed from the
better material for double helical gears by
surface of the tooth that is because of the high
performing analytical investigations. Structural,
contact stresses that are present between mating
Modal and Random Vibration analysis is
teeth, Failure theory by which the design aspects
performed by varying materials to determine better
are to no changed to reduce the contact stresses.
material by observing stresses, deformations,
B.Venkatesh ,V.Kamala, A.M.K.Prasad, 2010. frequencies and shear stresses. The materials
considered are Alloy Steel, Cast Iron, and
The main objective of this study is to structural
Structural Steel.
analysis on a high speed helical gear used in marine
engines, have been carried out. The dimensions of VI. MATERIAL SELECTION
the model have been arrived at by theoretical
Gear Material Selection material with best
methods. The stresses generated and the deflections
characteristic among alternatives.
of the tooth have been analyzed for different
materials. Finally the results obtained by theoretical
2320 –5547 @ 2013-2016 http://www.ijitr.com All rights Reserved. Page | 5052
M. Harika Chowdary* et al.
(IJITR) INTERNATIONAL JOURNAL OF INNOVATIVE TECHNOLOGY AND RESEARCH
Volume No.4, Issue No.6, October – November 2016, 5051-5054.
STEEL Diameter of gear Dg = m * Tg = 5 *54 = 270 mm
Density = 7850Kg/m3 *D
Circular pitch PC
Young’s Modulus (EX) = 200Gpa T
Poisson’s Ratio (PRXY) = 0.3
3.14 * 270
CAST IRON = 15.7mm
54
Density = 7810 Kg/m3
Face width b=4πm
Young’s Modulus (EX) = 240 Gpa
= 4*3.14*5 = 62.8 mm
Poisson’s Ratio (PRXY) =0.370
2000 * T
CAST STEEL Tangential force Wt =
Dg
Density = 7860 Kg/m3
Young’s Modulus (EX = 207 Gpa 2000 *143.3
1061.481N
Poisson’s Ratio (PRXY) = 0.29 270
Design Considering the module =5, W tan
Normal force Wn t
number of teeth = 18 and 200 full depth. sin
Speeds are considering as N = 1000 rpm Power o
1061 .481 * tan 20
transmitted = 15 KW
sin 20 o
Torque
=1129.60 mm
For 10000 rpm, T = 153.3 N-m
VII. MODELLING AND ANALYSIS
Parameter Symbol Formula Value
Pressure ϕ 20o
angle
Helix angle α 20o
Module
Addendum m 1*m 5mm
Dedendum 1.25*m
Minimum aw 2.25*m
total depth
1.5708*m 5mm
Thickness
of tooth dw m *Tp
Number of t 6.25mm
teeth pinion
Diameter of 11.25mm
pinion 10.25mm
Diameter of Dg m*Tg 270mm
gear Pc π*m 15.7mm
Circular 2.3Pc/tanα 62.8mm
pitch
b 2*m 10mm
face width
0.4*m 2mm
Work depth
2.05*m 10.25mm
Fillet radius
1.5708m 7.854 mm
Working
depth 0.25m 1.25 mm
Total
thickness Tt
Minimum
clearance
0.75
Cv= 0.14361
0.75 v
Number of tooth on gear T g =
Figures showing the modeling and stress analysis
3 *TP 3 *18 54 of Gears
2320 –5547 @ 2013-2016 http://www.ijitr.com All rights Reserved. Page | 5053
M. Harika Chowdary* et al.
(IJITR) INTERNATIONAL JOURNAL OF INNOVATIVE TECHNOLOGY AND RESEARCH
Volume No.4, Issue No.6, October – November 2016, 5051-5054.
VIII. RESULTS Hill Publishing Company Limited
Fourteenth reprint 2008.P[1].
[4]. Practical Gear Design And Manufacture,
STEPHEN P. RADZEVICH, Second
Edition, CRC Press Taylor, 2012, P(1).
[5]. Gear Materials Properties, and Manufacture,
J.R. Davis, Printed in the United States of
America .PP [1,4-8].
[6]. Machinery’s Handbook, ERIK OBERG,
FRANKLINK D. JONES, HOLBOOK L.
HORTON AND HENRY H. YFFEL,29th
Edition, P[2125].
[7]. Gear design simplified,franklin d. Jones and
henry h. Ryffel, Third Edition, Industrial
Press Inc, New York 1961.P(83,84).
[8]. DUDLEY’S GEAR HANDBOOK, Second
Edition ,Dennis P. Townsend Editor ،n
Chiefn Lewis Research Center, NASA, The
McGraw-Hill Companies , 2011,P(65,66).
[9]. Negash Alemu, ANALYSIS OF STRESSES
IX. CONCLUSIONS IN HELICAL GEARS BY FINITE
Structural, Modal and Fatigue analysis is done on ELEMENT METHOD, thesis, October
the herringbone gears for different materials Alloy 2007,PP(5,53).
Steel, Cast Iron and Structural steel. By observing [10]. Aarthy Vaidyanathan, AN
structural analysis results, the stress values are less EXPERIMENTAL INVESTIGATION OF
than the permissible strength for all materials. The HELICAL GEAR EFFICIENCY A Thesis,
deformation and stress values are less for Cast Iron 2009,PP(2,118).
than Structural Steel and Alloy Steel. By observing
the modal analysis results, the frequency values are [11]. Raghava Krishna Sameer.B, V.Srikanth,
less for Structural Steel so vibrations will be less CONTACT STRESS ANALYSIS OF
when Structural Steel and the deformation is also MODIFIED HELICAL GEAR USING
less. By observing the fatigue analysis results, the CATIA AND ANSYS, International Journal
damage is less for Alloy Steel than other materials. of Computer Science information and Engg,
So it can be concluded that using Alloy Steel is VOLUME2-SERIES4,2014,P(1,5).
better for this application due to the analysis [12]. B.Venkatesh ,V.Kamala ,A.M.K.Prasad,
results.. Design, Modelling and Manufacturing of
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