Abstract
Gear meshing is a complicated process, and is subjected to the simulation process in the following paper. A flexible quasi-static and dynamic finite element analysis (FEA) models were built, to calculate contact principal and shear stresses. Full sized 3D spur gears are simulated under different boundary conditions. The first model, was a quasi-static analysis, where torque was used as input; and the second model, which was transient dynamic analysis, where rotational speed was used as input. The static analysis showed high stress concentration at the tooth contact point and under the contacting surface. The dynamic analysis provided the highest stress value at the different stages of gear engagement points along the line of action. Analytical and simulation result were in agreement in general, and the use of the new simulation model was discussed.
Highlights
Gears are the main component in rotating machinery, they are mainly used in different kind of gearboxes, which are employed mainly in automobile industry, in wind energy for supplying wind turbines gearboxes
Gear contact stress is a main cause of fatigue and eventual failure, mainly the contact area will be subjected to a high stress concentration, which will cause fatigue, and the tooth will break under a stress lower than it could endure when put into service
An input torque equal to 23000 N.mm was applied to the pinion, and using Eq.3, Eq.4, Eq.5 and Eq.6 the contact stress at and under the contacting surface of the gear tooth was calculated using numerical computation package MATLAB
Summary
Gears are the main component in rotating machinery, they are mainly used in different kind of gearboxes, which are employed mainly in automobile industry, in wind energy for supplying wind turbines gearboxes. FEA is employed to monitor dynamic loading, tooth profile and meshing parameter are optimized and put under testing using the finite element analysis, the main aim is to reduce the stresses, leading to reduced fatigue subjected to the teeth and a better overall system reliability. The tooth stress distribution is an area of interest, because, providing the ability of a fast and reliable calculation, tooth profile modification and parameter optimization will be enabled, reducing maximum stress on selected areas. The maximum stress occur along the Y-axis, the principal stresses are presented bellow as follows:
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