Stress analysis of a gear using photoelastic method and Finite element method: Review

Abstract

Every day in our life, we use the gear, and it has become an integral and most used component. Gears have been in use for more than 100 years with different shapes and sizes in all the domains. For many decades gear has been the most researched component, and still, much research is going on. Pitting and surface hardness is understood by studying root stress and contact stress. The experimental (Photoelasticity), analytical, and Finite element method research helps develop new gear. Toothed gears transfer both motion and power during transmission. Power initiated at the first gear will have significant power loss when it reaches the final gear. When it comes to the assembled gear's performance and durability, we need to check on fatigue and reliability. The critical parameter for designing the gear is the contact stress created between the mating gear. In a comparison study for maximum contact stress, the load applied is around 300 N, and stress developed by the experimental method is 1775.1 N/mm2, and using the FEM is 1781.1 N/mm2, with a 1% error. Asymmetric gears are the replacement for conventional involute gears, they also provide the required strength, and also, there is a reduction in the weight of the gear. Materials like Metal, Epoxy resin, Polymer, Etc are used to manufacture gear. Composite gears can transmit power up to 175 KW.