INTERNATIONALJOURNALOFAPPLIEDENGINEERINGRESEARCH,DINDIGUL

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Modeling andAnalysisofAluminumA360AlloyHelicalGear forMarine

Applications
B.Venkatesh1, V.Kamala2 A.M.K.Prasad3

1 AssociateProfessor,MED,Vardhaman CollegeofEngg,Hyderabad,India
2 Professor,MED,MJCET,HyderabadDGM(Retd),BHELR&D,Hyderabad,India
3 Professor,&Head,MED,OsmaniacollegeofEngg,OsmaniaUniversity,Hyderabad,India
bvt_2275@yahoo.co.in

Abstract
Gears are one of the most critical components in mechanical power transmission systems. Todays
competitive business in the global market has brought increasing awareness to optimize the gear
design.Thegearsaregenerallyusedtotransmitpowerortorqueandtheefficiencyoftransmissionis
very high when compared to other kind of transmissions. The helical gear offers high contact and
more friction which avoids slippage when compared to spur gear. To estimate the bending stress,
threedimensionalsolidmodelsfordifferentnumberofteetharegeneratedbyCATIAthatispowerful
and modern modeling software and the numerical solution is done by ANSYS, which is a finite
elementanalysispackage.TheanalyticalinvestigationisbasedonLewisstressformula.Theaimof
thepresentstudyistofocusonreductionofweightandtherebyreducingtheunbalanceforcessetup
inthesystem.
Keywords:Geardesign,Computeraidedanalysis,highspeedhelicalgear,dynamicanalysis
1.Introduction
The motion from one shaft to another shaft may be transmitted with belts, ropes and chains. These
methods are mostly used when the two shafts are having long center distance. But if the distance
betweenthetwoshaftsisverysmall,thengearsareusedtotransmitmotionfromoneshafttoanother.
Incaseofbeltsandropes,thedriveisnotpositive.Thereisslipandcreepthatreducesvelocityratio.
Butgeardriveisapositiveandsmoothdrive,whichtransmitvelocityratio.Gearsareusedinmany
fieldsandunderawiderangeofconditionssuchasinsmallerwatchesandinstrumentstotheheaviest
and most powerful machineries like lifting cranes. Gears are most commonly used for power
transmissioninallthemoderndevices.Thesetoothedwheelsareusedtochangethespeedorpower
between two stages (input and output). They have gained wide range of acceptance in all kinds of
applicationsandhavebeenusedextensivelyinthehighspeedmarineengines.Inthepresenteraof
sophisticatedtechnology,geardesignhasevolvedtoahighdegreeofperfection.Thedesign
andmanufactureofprecisioncutgears,madefrommaterialsofhighstrength,havemadeit
possibletoproducegearswhicharecapableoftransmittingextremelylargeloadsatextremely
highcircumferentialspeedswithverylittlenoise,vibrationandotherundesirableaspectsof
gear drives. Helical gears are the modified form of spur gears, in which all the teeth are cut at a
constant angle, known as helix angle, to the axis of the gear, where as in spur gear, teeth are cut
paralleltotheaxis.Helicalgearsarealsoemployedtotransmitpowerbetweentwoshaftsparallelto
the axis. The following are the requirementsthat mustbe met in the designof gear drive. The gear
teethshouldhavesufficientstrength,sothattheywillnotfailunderstaticanddynamicloadingduring
normal running conditions. The gear teeth should have clear characteristics so that their life is
satisfactory, the use of space and material should be economical. The alignment of the gears and
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deflections of the Shafts mustbeconsidered,because they affect the Performance of the gears.The
lubrications of the gears mustbe satisfactory. Currently the popular standards are ISO and AGMA.
These standards vary in selected approaches as well as models and methods resulting in different
design solutions obtained for the same gear under the same set of working conditions. Gear
transmissions affect energy consumption during usage, vibration, noise and warranty costs among
others factors. These factors are critical in modern competitive, manufacturing, especially in the
aviation industry which demands exceptional operations requirements concerning high
reliability and strength, low weight and energy consumption, low vibrations andnoise. Considering
their reliability and efficiency are someof the most important factors,problems ofdistributions of
loadsandconsequently,distributionofstressesinthewholegeartransmission,particularlyinteeth
ofmatinggears,needtobethoroughlyanalyzed.Geartransmissionsarewidelyusedinvarious
industries and their efficiency and reliability are critical in the final product performance
evaluation.
2.Designmethodology
2.1GeardesignbasedonAGMAProcedure:Thedesignofhelicalgearisalmostsimilartospur
geardesignwithslightmodificationsinLewisandBuckinghamequationsduetohelixangle.
AccordingtoLewisequation,thebeamstrengthofhelicalgeartoothisgivenby
s b pmn yv ,Where[sb ]=AllowablecontactstressinN/mm2 ,b=Facewidthofgearblank=10
Fb= [ b]
mn ,Mn=Normal module which must be standardized., yv=Lewis form factor which depends on the
Z

3
virtualnumberofteethZ = Cos b ,Forsafeworking,thebeamstrengthshouldbegreaterthan
v

thedesigntoothload
Ft Ks Cv
v
FD which is given by
, The values of Ka, Cv, v etc., are calculated
similar to spur gears. The dynamic load acting on helical gear tooth may be found out using
21vCbcos2 b+ Ft cosb
Fd = Ft +
21v+ Cbcos2 b + Ft
Buckingham equation as
and the wear tooth load is given by
d1 b Q Kw
Fw =
Cos2b
The values of Q and Kw etc., are all common with spur gears. The design procedure is also very
similartospurgears.
FD = Ft Ks Cv =

3.Resultsanddiscussion
3.1Theoreticaldesigncalculations
Herethetheoreticalcalculationsfordesignareperformedbyusingtheinputparameterssuchaspower
for marine high speed engine P=9000KW, speedof thepinion =3500 rpm, gear ratio=7 and helix
angle=250
Minimumcenterdistancebasedonsurfacecompressionstrengthisgivenby
2

0.7
E[M t ]
a ( 7 + 1)3
x
iy
sc

[Table8,PSG]
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Calculationsforaluminumalloy[98%Al2O3,0.40.7%Mn,0.40.7&Mg]
MaterialSelection:LetthematerialforPinion&GearisAluminumAlloy.
Itsdesigncompressivestress&bendingstressesare[c=25000kgf/cm2],[b=3500kgf/cm2][17]
PropertiesforAluminumAlloy:DensityofAluminumAlloy()=3900kg/m3
YoungsModulus=340x103N/mm2 ,PoissonsRatio(v)=0.220,i=7,=0.3,[Table9,10PSG]
[MT]=MTkdk,MT=97420KW/N
kd k=1.3,[MT]=MT kDk=(97420x9000x1.3)/3500=325661kgfcm
Now,minimumcentredistancebasedonthesurfacecompressivestrengthisgivenby
0.7
(i+ 1)x3 xE[Mt ]
sc
a
(iy )
a>59.59cm=60cm
Minimummodulebasedonbeamstrength:
Mn>1.15cosx{[Mt]/(Yv bm Z1)1/3}[Table8,PSG]
LetZ1=18,m=10[Table11,PSG8.14]
VirtualnumberofteethZ v =Z 1/cos2 =18/0.744=25
LewisformfactorYv(forZv=25)=0.4205
mn >1.15cos25x{325661.14/(0.4205x3500x10x18)}1/3
>1.11cm,mn >11.16mm
Butformn=1116mm,candbare>[c]&[b]alsoFS<FDwhichmakesdesignunsafe.
Somn =18mm=1.8cm,No.ofteethofpinion,Z1=(2acos)/mn(i+1)=12
Butinordertoavoidinterference,Z1 istakenas18,No.ofteethongear,Z2=iZ1 =126
Diameterofthepinion=(mnxZ1)/cos=(1.6x18)/cos25=35.74cm
Diameterofthegear(d2)=Id1 =7x35.74=250.24cm,Centerdistance(a)=(d 1+d2)/2=142.99cm
Facewidthb=.a=0.3x142.99=43cm
CheckingCalculations:
i +1 i+ 1
xE[Mt] [s c]
ib
c=0.7x a

b=0.7x{(i+1)/(a.b.Mn.Yv)}[Mt] [c]
BasedontheCompressiveStresses:
c=(0.7x8x325661.14)/(88.4x43x0.4205)=228.35N/mm2
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Basedonthebendingstressb=178.59N/mm2
fromthecalculations,candbare[c]&[b]valuesofgivenmaterials,Thereforeourdesignis
safe.Addendum,mn =18mm,
Dedendum=1.25xmn =22.5mm,
Tipcirclediameterofthepinion=d1+(2xaddendum)=357.4+3.6=393mm
Tipcirclediameterofgear=d2+(2xaddendum)=2502+3.6=2538mm
Rootcirclediameterofpinion=d1 (2xaddendum)=357.4 3.6=321.4mm
Rootcirclediameterofgear=d2 (2xaddendum)=2502 3.6=2466mm
Whenthe geartransmitsthepowerP,thetangential forceproducedduetothepowerisgivenby Ft
=(Pxks)/v
V =

pxD
pxNp
60 x1000

px357.4x3500
60x1000

= 65.42m/s Ft =
,

9000x103 x2
= 275145.21N
65.42

Lewisderivedtheequationforbeamstrengthassumingtheloadtobestaticwhenthegearisrunning
at high speeds, the gears may be subjected to dynamic effect. To account for the dynamic effect, a
factorCvknownasVelocityfactorordynamicfactorisconsidered.Thedesigntangentialforcealong
withdynamiceffectisgivenby
PxksxCv
FD = FtxCv=
V
The velocity factor Cv is developed by Barth. It depends on the pitch line velocity and the
workmanshipinthemanufactureanditsisgivenbyCv=(5.5+v1/2)/5.5forV>20m/s.
WhereFt =275145.21N,Ks=2,V=65.42m/s,
5.5+ 65.42
Cv =
= 2.47
5.5
FD=275.145x2.47=679771.90N
AccordingtoLewisequation,thebeamstrengthofhelical geartoothisgivenby
FS=[b].b..mn.yv=(1.75x341)x430xx18x0.4205=6101677.663N(or)
FS=[b].b..mn.yv=4000x43xx1.5x0.4205=4089938.94N
Since, FS > FD, Ourdesign issafe. When the power is transmitted through gears, apart from static
(steady) loadproducedby the power, somedynamic loads are also appliedon the gear tooth dueto
reasonslikeinaccuraciesoftoothprofilesanddeflectionsoftoothunderload.Consideringtheabove
conditions Buckingham desired an equation to find out the maximum load acting on the gear tooth
whichisgivenbyFd=Ft+Fi whereFd =Maximumdynamicload,Ft=Staticloadproducedbythe
power ,Fi = Incremental load due to dynamic action Incremental load depends on the pitch line
velocity,facewidth,ofageartooth,gearmaterials,accuracyofcutandthetangentialloadanditsis
givenby
0.164Vm(cbcos2 b + Ft)Cosb
Fi =
0.164Vm + 1.485 cbcos2 b + Ft
Where,Vm=Pitchlinevelocityinm/s,b=Facewidthofthegeartoothinmm
C=Dynamicfactor(or)DeformationfactorinN/mm.[17]
Here, C=11860xe,C=11860x0.026=308.36N/mm,Ft=137572.60N,
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Vm=65.42m/s=65.42x103mm/sec,b=38.16cm=381.6mm,
0.164Vm(cbcos2 b + Fb)Cosb
Fd = Ft +
0.164Vm + 1.485 cbcos2 b + Ft
Fd =137572.60+

=250,Fd =Ft+Fi

0.164x65.42x(308.36x430xcos2 25+ 137572.60)Cos25

0.164x65.42+ (1.485 308.36x430xcos2 25+ 137572.60)

2396542.95
Fd =137572.60+
= 140776.62N
747.98
SinceFs>Fd,ourdesignissafe.

Oneofthemostpredominantgearfailuresisthefailureofgeartoothduetopitting.Thispittingfailure
occurswhenthecontactstressesbetweenthetwomeshingteethexceedthesurfaceendurancestrength
of the material. In order to avoid this type of failure the proportions of gear tooth and the surface
propertiessuchassurfacehardnessshouldbeselectedinsuchaway thatthewearstrengthofthegear
toothismorethantheeffectiveloadbetweenthemeshingteeth.
BasedonHertztheoryofcontactstresses,Buckinghamderivedanequationforwearstrengthofgear
tooth which is given by Fw = (d 1.b.Q.Kw)/cos2 , Where Fw = Max or limiting load for wear in
Newtons,
d1=Pitchcirclediameterofpinioninmm,b=Facewidthofthepinioninmm
Q=Ratiofactor=2i/(i+1)=1.75,Kw=2.553N/mm2 [Table25.37JDB]
d 1 .b.Q.Kw
cos
b
d 1 =357.4mm,b=430mm,Fw=
Fw=357.4x430x1.75x2.553/cos225=900086.75N,Fd=140776.62NSinceFw>Fdourdesignin
safe.
2

3.2SolidModelingandFEMPackage
SolidModelingisgeometricalrepresentationofarealobjectwithoutlosinginformationtherealobject
wouldhave.Ithas volumeandtherefore,ifsomeoneprovidesavaluefordensityofthematerial,it
will havemassandinertia.Unlikethesurfacemodel,ifonemakesa holeorcutinasolidmodel,a
new surface is automatically created and the model recognizes which side of the surface is solid
material. The most useful thing about solid modeling is that it is impossible to create a computer
modelthatisambiguousorphysicallynonrealizable.AmodeliscreatedusingCATIAsoftwareand
thenitisretrievedintoANSYSusingIGESfiles.Theproportionsofgearcomingoutfromtheoretical
designandwhichareusedtocreatethemodel.
3.3Analysis
Significant Development in analysis of strength properties of gear transmission follows the
achievements in computation design, simulation of meshing and tooth contact analysis made by
Lewiki,Handschuh.They carried out 2D analyses using finite element method, boundary element
methods & Compared the results to experimental ones validated crack simulation based on
calculated stress intensity factors and mixed mode crack angle prediction. In practice, simplified
formulasareusuallyusedingeartransmissiondesign.Theyenablesestimationofstressesattoothroot
with accuracy acceptable for engineering design. In every case, strength properties of gear
transmissions are strongly influenced by gear geometry, applied manufacturing processes, and
dimensionalaccuracyofmanufacturedgears.
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3.3.1Vibrationanalysis
Itisusedtotestthematerialagainstrandomvibrations,shockandimpact.Eachoftheincidentsmay
act on the natural vibration frequency of the material, which in turn, may cause resonance and
subsequencefailure.
3.3.1.2 Modal analysis: It is the application of the FEM, used to determine the vibration
characteristics(naturalfrequenciesandmodeshapes)ofastructureofamachinecomponentwhileitis
beingdesigned.Thenaturalfrequenciesandmodeshapesareimportantparametersinthedesignofa
structurefordynamicloadingconditions.ModalanalysisistheANSYSfamilyofproductsanditisa
linearanalysis.Anynonlinearity,suchasPlasticityandcontact(gap)elementsareignoredevenifthey
aredefined.Youcanchoosefromseveralmodeextractionmethods:subspace,BlockLanczos,power
Dynamics,reduced,unsymmetrical,anddamped.Thedampedmethodallows youtoincludedampin
inthestructure.

Figure3.1:VonmissesstressforAluminumalloy

Figure3.2: Modeshape1forAluminumalloy

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Figure 3.3: Modeshape2forAluminiumAlloy

Figure3.4: Modeshape 3forAluminiumAlloy

Figure3.5: Modeshape 4forAluminiumAlloy

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Figure3.6: Modeshape 5forAluminiumAlloy

Figure3.7: Modeshape6forAluminiumAlloy

Figure3.8: Modeshape7forAluminiumAlloy

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Figure3.9: Modeshape 8forAluminiumAlloy

Figure3.10: Modeshape9forAluminiumAlloy

Figure3.11: Modeshape10forAluminiumAlloy
TheTable3.1&graphshowsthemodalanalysisforaluminumalloys

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Table3.1: ModalanalysisforAluminium alloys

Frequency
6500
8507
9535
9661
9954
10057
10284
12094
12096
12657

Displacement
4.812
7.421
7.233
7.373
6.122
6.62
6.711
9.538
9.854
8.926

3.3.1.2 Modal analysis: It is the application of the FEM, used to determine the vibration
characteristics(naturalfrequenciesandmodeshapes)ofastructureofamachinecomponentwhileitis
beingdesigned.Thenaturalfrequenciesandmodeshapesareimportantparametersinthedesignofa
structurefordynamicloadingconditions.ModalanalysisistheANSYSfamilyofproductsanditisa
linearanalysis.Anynonlinearity,suchasPlasticityandcontact(gap)elementsareignoredevenifthey
aredefined.Youcanchoosefromseveralmodeextractionmethods:subspace,BlockLanczos,power
Dynamics,reduced,unsymmetrical,anddamped.Thedampedmethodallowsyoutoincludedamping
inthestructure.
4.Conclusions
1. Vonmisses stress was obtained by theoretical and Ansys software for Aluminum alloy, values
obtainedfromANSYSarelessthanthatofthetheoreticalcalculations.
2.Thenaturalfrequenciesandmodeshapesareimportantparametersinthedesignofastructurefor
dynamicloadingconditions,whicharesafeandlessthantheothermaterialslikesteel.
3.Aluminumalloyreducestheweightupto5567%comparedtotheothermaterials
4. Aluminum is having unique property (i.e. corrosive resistance), good surface finishing, hence it
permitsexcellentsilentoperation.
5.Weightreductionisaveryimportantcriterion,inordertominimizetheunbalancedforcessetupin
themarinegearsystem,therebyimprovesthesystemperformance.

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Gr aphDis place m e ntV s Fre que ncy
140 00

120 00

100 00

80 00
Series1
Series2
60 00

40 00

20 00

0
1 2

3 4

7 8

9 10

D i sp la ce ment

Figure3.11:GraphshowingModalanalysisforAluminiumalloy
6.Hencealuminumalloyisbestsuitedformarinegearinthehighspeedapplications.
7.Asafuturework,harmonicandtransientanalysisofthegearcanbeperformedtofindouttheeffect
ofvariouscyclicloadingconditionsalongwithtemperaturevariations.
Acknowledgements
First author is grateful to Dr.T.Srinivasulu, Principal VCE shamshabad and Dr.G.V.Rao Head
MechanicalEngineeringDepartmentfortheirvaluablesupport.Heisalsothankfultothemanagement
oftheinstitutefortheencouragement,support,andcooperationduringtheentirework.
5.References
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ofaspurgear,JournalofEngineeringandAppliedSciences2(12)pp17431747.
2. Zeping Wei., 2004Stresses and Deformations in Involute spur gears by Finite Element
method,M.S,Thesis,CollegeofGraduateStudiesandresearch,UniversityofSaskatchewan,
Saskatchewan.
3. DarleW.Dudley,1954,Handbookofpracticalgeardesign
4. Alecstrokes,1970,Highperformanceofgeardesign
5. Maitra,G.M,2004,HandBookofGearDesign,TataMcGrawHill,NewDelhi..
6. S.Md.Jalaluddin.,2006,MachineDesign,Anuradhapublications,Chennai.
7. ThirupathiChandrupatla,AshokD.Belegundu,IntroductiontofiniteelementinEngineering,
2003
8. PSG,2008.Designdata,KalaikathirAchchagampublishers,Coimbatore,India.
9. S.Mahalingam,R.E.DBishop,1974,DynamicloadingofGeartooth,Journalofsoundand
vibration, 36(2),pp179189
10. S.H.Choi,J.Glienicke,D.C.Han,K.Urlichs,April1999,DynamicGearLoadsduetocoupled
lateral,TorsionalandAxialVibrationsinahelicalGearedSystem,Journalofvibrationand
acoustics,Vol121/141.

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