Stresses and deformations in involute spur gears by finite element method

Abstract

This thesis investigates the characteristics of an involute gear system including contact stresses, bending stresses, and the transmission errors of gears in mesh. Gearing is one of the most critical components in mechanical power transmission systems. Transmission error is considered to be one of the main contributors to noise and vibration in a gear set. Transmission error measurement has become popular as an area of research on gears and is possible method for quality control. To estimate transmission error in a gear system, the characteristics of involute spur gears were analyzed by using the finite element method. The contact stresses were examined using 2-D FEM models. The bending stresses in the tooth root were examined using a 3-D FEM model. Current methods of calculating gear contact stresses use Hertz’s equations, which were originally derived for contact between two cylinders. To enable the investigation of contact problems with FEM, the stiffness relationship between the two contact areas is usually established through a spring placed between the two contacting areas. This can be achieved by inserting a contact element placed in between the two areas where contact occurs. The results of the two dimensional FEM analyses from ANSYS are presented. These stresses were compared with the theoretical values. Both results agree very well. This indicates that the FEM model is accurate. This thesis also considers the variations of the whole gear body stiffness arising from the gear body rotation due to bending deflection, shearing displacement and contact deformation. Many different positions within the meshing cycle were investigated.