Design and Analysis of Helical Gear

A Dissertation submitted to the Jawaharlal Nehru Technological University,

Hyderabad in partial fulfilment of the requirement for the award of degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

Submitted by

N.G.PRIYANKA (14B81A03C3)
B.SAI DIGVIJAY GOUD(14B81A03F1)
K.SAI PRASAD (14B81A03G0)

Under the Guidance of

Mr. T.Venkatesh
Assistant Professor

Department of Mechanical Engineering

CVR COLLEGE OF ENGINEERING
(An UGC Autonomous Institution & Affiliated to JNTUH)
Vastunagar, Mangalpalli (V), Ibrahimpatnam (M), Ranga Reddy (Dist.) - 501510,
Telangana State
2017-18
 CVR COLLEGE OF ENGINEERING
(An UGC Autonomous Institution & Affiliated to JNTUH)
Vastunagar, Mangalpalli (V), Ibrahimpatnam (M),
Ranga Reddy (Dist.) - 501510, Telangana State.

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that the project work entitled “Design and Analysis of Helical Gear”

is being submitted by N.G.PRIYANKA (14B81A03C3), B.SAI DIGVIJAY GOUD

(14B81A03F1), K.SAI PRASAD (14B81A03G0) in partial fulfilment of the requirement for

the award of the degree of Bachelor of Technology in Mechanical Engineering, during the

academic year 2017-2018.

Project Guide Head of the Department

Mr.T.Venkatesh Dr. M. Venkata Ramana

Assistant Professor Professor

Project Coordinator External Examiner

ii
Dr. G. Venkatesha Prasanna

Professor

iii
 DECLARATION

I hereby declare that this project report titled “DESIGN AND ANALYSIS OF

HELICAL GEAR ” submitted to the Department of Mechanical Engineering, CVR College

of Engineering is a record of original work done by me under the guidance of Mr.

T.Venkatesh. The information and data given in the report is authentic to the best of my

knowledge. This project report is not submitted to any other university or institution for the

award of any degree or diploma or published any time before.

N.G.PRIYANKA (14B81A03C3)
B.SAI DIGVIJAY GOUD (14B81A03F1)
K.SAI PRASAD (14B81A03G0)

Date: 3rd April 2018

Place: Hyderabad

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 ACKNOWLEDGEMENTS

This project could not have been possible without the help of many individuals who have
guided us and constantly gave the motivation to do it.

We would like to thank Dr. K.S. Nayanathara, Principal, CVR College of Engineering for
providing us the opportunity for doing this project work.

We would like to thank Dr. M. Venkata Ramana, Head of Department, Mechanical

Engineering for giving us the opportunity to do this project work.

We would like to thank Dr. P. UmaMaheshwera Reddy, Professor, Mechanical

Engineering for giving us the opportunity to do this project work.

We would like to express our deepest happiness to Mr.T.Venkatesh, Assistant Professor,

Project Guide, Mechanical Department for his esteemed guidance and involvement with us
throughout the project work. He has taught us more than what we have ever learned from a
text book and gave us deep insights about industry standards and procedures which are
followed during manufacturing and made sure that we could learn them and apply it not only
for this project, but also apply these principles in our professional life also.

We would like to thank Dr. G. Venkatesha Prasanna, Professor, Project Coordinator,

Mechanical Department for giving us the guidance and layout involved in a project work.

We would like to thank Dr. K. Kishore Kumar, Associate Professor, Project Coordinator,
Mechanical Department for giving us the guidance in a preparing the project presentation.

We would like to thank Mr. M. Kishore Kumar, Assistant Professor, Project Coordinator,
Mechanical Department for giving us the guidance in report writing in a project work.

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We would like to thank all the Lab Assistants who have helped us throughout the duration of
the project in every manner possible.

Last but not the least we would like to thank our parents for their support and cooperation.

vi
 ABSTRACT

Helical gears are widely used in industry where the power transmission is required at

heavy loads with smoother and noiseless operation. Helical gear are generally used to

transmit power or torque for transmission at very high speed when compared to other

kind of gear transmissions this application are explain the design the helical gear with

defined specification. It’s have an involving modern design, specific character, specific

materials, with consideration of analysis of force, and its mechanical properties. In this

project we design the helical by using solid works and perform the analysis by using solid

works simulation by using different materials and different number of teeth and changing

their helix angle.

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i
 INDEX

DECLARATION……………………………………………………………………………..III
ACKNOWLEDGEMENTS…………………………………………………………………..IV
ABSTRACT……………………………………………………………………………………V
CHAPTER I……………………………………………………………………………………1
1. INTRODUCTION TO GEAR………………………………………………………………………………………….1
GEAR TERMINOLOGY AND NOMENCLATURE………………………………………………………………….3

CHAPTER II ........ ……………………………………………………………………………5

INTRODUCTION TO HELICAL GEAR……………………………………………………………………….5
CONCEPT……………………………………………………………………………………………………………6
HELICAL GEAR CHARACTERISTICS………………………………………………………………………………6

HELICAL GEAR GEOMETRY AND NOMENCLATURE…………………………………………………………...7

HELICAL GEAR TOOTH PROPORTIONS…………………………………………………………………………...9

HELICAL GEAR-TOOTH FORCE ANALYSIS………………………………………………………………………9

HELICAL GEAR BENDINSTRENGTH…………………………………………………………………………….....9

ADVANTAGES…………………………………………………………………………………………………....10
DISADVANTAGES……………………………………………………………………………………………….11
APPILICATIONS……………………………………………………………………………………........11
TYPE OF MATERIAL USED………………………………………………………………………………......12
CHEMICAL COMPOSITION……………………………………………………………………………………….....12

MECHANICAL PROPERTIES…………………………………………………………………………………………12

THERMAL REFINING………………………………………………………………………………………. .....14

INDUCTION HARDENING…………………………………………………………………………………......14
CHAPTER III…………………………………………………………………………………...15
2. LITERATURE REVIEW………………………………………………………………………………………………………15
CHAPTER IV……………………………………………………………………………………16
3. PROJECT SCHEDULE…………………………………………………………………………………………………..16
CHAPTER V……………………………………………………………………………………..17
4. DESIGN OF HELICAL GEAR INTRODUCTION TO SOLID WORKS……………………………………………….17
INITIAL DESIGN…………………………………………………………………………………………………………18

DESIOGN OF HELICAL GEAR COMPLETED BY CHANGING THEIR HELIX ANGLE…………………………..18

CHAPTER VI…………………………………………………………………………………….21
 ANALYSIS………………………………………………………………………………………………………………..21
LOAD ANALYSIS……………………………………………………………………………………………………….22
STATIC LOAD ANALYSIS(For Helix angle 21.5)…………………………………………………………….22
EQUIVALENT STRESS ANALYSIS…………………………………………………………………………………….23

DEFORMATION ANALYSIS…………………………………………………………………………………………….25

MAXIMUM SHEAR ELASTIC STRAINANALYSIS………………………………………………………...………….27

FATIUGE LOAD ANALYSIS………………………………………………………………………………………......... 28

STATIC LOAD ANALYSIS(For Helix angle 15) ......................................................................................... .32

EQUIVALENT STRESS ANALYSIS……………………………………………………………………………...33

DEFORMATION ANALYSIS………………………………………………………………………………………35

MAXIMUM SHEAR ELASTIC STRAINANALYSIS………………………………………………………...……36

FATIUGE LOAD ANALYSIS……………………………………………………………………………………….39

CHAPTER VII………………………………………………………………………………………..40
5. RESULTS AND DISCUSSIONS..…………………………………………………………………………………….40
CHAPTER VII……………………………………………………………………………... 44
Future Work………………………………………………………………………….. ..44
CHAPTER IX………………………………………………………………………………..46
6. REFERENCES……………………………..………………………………………………………..…………………..46
 List of Tables
Table 2.7.4 Heat Treatment and Hardness for SCM440 ............................................... ……………..13

Table 2.8.3 Heat Treatment and Hardness for S45C .................................................... ……………...14

Table 6.1.2 Equivalent stress Analytical Observation for S45C Material(Helix angle 21.50)…………22

Table 6.1.3 Equivalent stress Analytical Observation for SCM440 Material…………………………23

Table 6.1.4 Equivalent stress Analytical Observation for Structural steel ........................................... 24

Table 6.2.1:Total Deformation Analytical Observation for S45C Material .......................................... 25

Table 6.2.2: Total Deformation Analytical Observation for SCM440 Material .................................... 25

Table 6.2.3: Total Deformation Analytical Observation for Structural steel ....................................... 26

Table 6.3.1:Maximum Shear Elastic Strain Analytical Observation for S45C Material ........................ 27

Table 6.3.2: Maximum Shear Elastic Strain Analytical Observation SCM440 Material ....................... 27

Table 6.3.3: Maximum Shear Elastic Strain Analytical Observation Structural steel............................ 28

Table 6.5: Results and Discussion ..................................................................................................... …30

Table 6.6.1 :Equivalent stress Analytical Observation for S45C Material(Helix angle 150)…………..32

Table 6.6.2 :Equivalent stress Analytical Observation for SCM440 Material ...................................... 32

Table 6.6.3 :Equivalent stress Analytical Observation for Structural steel…………………………...32

Table 6.7 :Total Deformation Analytical Observation for S45C Material ............................................ 33

Table 6.7.1: Total Deformation Analytical Observation for SCM440 Material .................................... 34

Table 6.7.2: Total Deformation Analytical Observation for Structural steel ....................................... 34

Table 6.8:Maximum Shear Elastic Strain Analytical Observation for S45C Material ........................... 35

Table 6.8.1: Maximum Shear Elastic Strain Analytical Observation SCM440 Material ....................... 37

Table 6.8.2: Maximum Shear Elastic Strain Analytical Observation Structural steel............................ 41

Table 7.1.1: Results and Discussion ...................................................................................................... 43

 List of Figures
Figure 1.1:Design of Gear ....................................................................................................................... 1

Figure1.4: Gear Nomenclature ............................................................................................................... 3

Figure 2.1:Design of Helical Gear ............................................................................................................ 5

Figure 2.1.1:Helix angle........................................................................................................................... 6

Figure 2.3:Portion of Helical Rack ........................................................................................................... 6

Figure 2.3.1:View of Helical Gear in normal Transverse Section ............................................................ 7

Figure 2.3.2:Tooth Force and its components on a Right Helical Gear………………………………9

Figure 5.1:Modeling of Helical Gear ..................................................................................................... 18

Figure 5.2:Initial Design of Helical Gear ............................................................................................... 19

Figure 5.3:Design of Helical Gear completed in solid works………………………………………….20

Figure 6.1.2 Equivalent stress Analysis For S45C Material(Helix angle 21.50) ..................................... 22

Figure 6.1.3 Equivalent stress Analysis for SCM440 Material ............................................................. 23

Figure 6.1.4 Equivalent stress Analysis for Structural steel…………………………………………24

Figure 6.2.1:Total Deformation Analysis for S45C Material................................................................ 25

Figure6.2.2: Total Deformation Analysis for SCM440 Material .......................................................... 26

Figure 6.2.3: Total Deformation Analysis for Structural steel ............................................................. 26

Figure6.3.1:Maximum Shear Elastic Strain Analysis for S45C Material .............................................. 27

Figure 6.3.2: Maximum Shear Elastic Strain Analysis for SCM440 Material ..................................... 27

Figure 6.3.3: Maximum Shear Elastic Strain Analysis for Structural steel………………………… ………..28

Figure 6.6.1 :Equivalent stress Analytical Observation for S45C Material(Helix angle 150)……….. 32

Figure 6.6.2 :Equivalent stress Analytical Observation for SCM440 Material ................................... 33

Figure 6.6.3 :Equivalent stress Analytical Observation for Structural steel…………………………33

Figure 6.7 :Total Deformation Analytical Observation for S45C Material .......................................... 34

Figure 6.7.1: Total Deformation Analytical Observation for SCM440 Material .................................. 34
Figure 6.7.2: Total Deformation Analytical Observation for Structural steel ..................................... 35

Figure 6.8:Maximum Shear Elastic Strain Analytical Observation for S45C Material………………..36

Figure 6.8.1: Maximum Shear Elastic Strain Analytical Observation SCM440 Material ..................... 36

Figure 6.8.2: Maximum Shear Elastic Strain Analytical Observation Structural steel ......................... 37
 Chapter I

1.Introduction to gear:

Gearing is one of the most effective methods transmitting power and rotary motion from the

source to its application with or without change of speed or direction. Gears will prevail as a

critical machine element for transmitting power in future machines due to their high degree of

reliability and compactness. The rapid development of heavy industries such as vehicle,

shipbuilding and aircraft industries require advanced application of gear technology.

A gearbox consists of a set of gears, shafts and bearings that are mounted in an enclosed

lubricated housing. They are available in a broad range of sizes, capacities and speed ratios.

Their function is to convert the input provided by the prime mover into an output with lower

speed and corresponding higher torque. In this thesis, analysis of the characteristics of helical

gears in a gearbox is studied using finite element analysis.

The crucial requirement of effective power transmission in various machines, automobiles,

elevators, generators, etc…. has created an increasing demand for more accurate analysis of the

characteristics of gear systems. For instance in automobile industry highly reliable and

lightweight gears are essential. Further more the best way to diminution of noise in engine

requires the fabrication of silence gear system. Noise reduction in gear pairs is especially

critical in the rapidly growing today’s technology since the working environment is badly

influenced by noise. The most successful way of gear noise reduction is attained by decreasing

of vibration related with them. The reduction of noise by vibration control can be achieved

through a research endeavor by an expert in the field.

1
 Fig 1: Design of gear

1.1 Advantages of Gear

1.Compact drive on account of small centre distance

2. High efficiency, reliable service and simple operation.

3. Positive drive due to negligible slip between contacting surfaces

4. Give higher speed ration and can transmit higher power

5. It is possible to transmit power between parallel, non parallel, intersecting and non intersecting shafts

1.2 Limitation of Gears

1. The error in tooth meshing may cause undesirable vibrations and noise during operation

2. Costlier than belts and chain drivers

3. Power cannot be transmitted over long distances.

4. Precise alignment of shafts is required

5. Require continuous lubrication.

1.3 Application of Gears

1.Metal cutting machine tools

2.Automobiles

3.Tractors
2
4.Hoisting and transporting machinery

5.Rolling mills

3
 1.4 Gear Terminology and Nomenclature

Fig 1.4 Gear Nomenclature

`1.4.1 Diametral Pitch (DP)

The diametral pitch describes the gear tooth size. The diametral pitch is expressed as the number of teeth

per inch of pitch diameter. Larger gears have fewer teeth per inch of diameter pitch. Anotherway of

saying this; gear teeth size varies inversely with diametral pitch.

1.4.2 Pitch Diameter (D)

The pitch diameter refers to the diameter of pitch circle .If the gear pitch is known then the pitch

diameter is easily calculated using the following formula,

PD =N/P

where, PD=pitch diameter N=number of teeth on the gear P = diametral pitch (gear size)

1.4.3 Pitch Circle

The pitch circle is the geometrical starting point for designing gears and gear trains. Gear trains refer
4
to systems of two or more meshing gears. The pitch circle is an imaginary circle that contacts the

pitch circle of any other gear with which it is in mesh. See fig. below.

1.4.4 Addendum

The addendum refers to the distance from the top of the tooth to the pitch circle.

1.4.5 Dedendum

The dedendum refers to the distance from the Pitch circle to the root circle.

1.4.6 Clearance(C)

Refer to the radial distance between the top and bottom of gears in mesh. Some machinists and
mechanics refer to clearance as “play” or the degree of looseness between mating parts.

1.4.7 Whole Depth (WD)

Refers to the distance from the top of the tooth to the bottom of the tooth .The whole depth is

calculated using this formula:

WD=2.157/P

Where, P=pitch

1.4.8 Pressure Angle (PA) (CHOOSE EITHER 14.5 OR 20 DEGREE)

The pressure angle figure into the geometry or form of the gear tooth. It refers to the angle through

which force are transmitted between meshing gears.14.5-degree Tooth forms were the original

“standard” gear design. While they are still widely available, the 20 degree PA gear tooth forms

have wider bases and can transmit Greater loads. Note: 14.5-degree PA tooth forms will not mesh

with 20-degree PA teeth .Be certain to verify the pressure angle of the gears you use.
5
1.4.9 Center Distance

The center distance of 2 spur gears is the distance from the center shaft of one spur Gear to the center

shaft of the other. Center to center distance for two gears in mesh can be calculated with this formula.

Center-to-Center distance =PDgearA+PDgearB/2

6
 CHAPTER 2

2.1 Introduction to helical gear:

Helical gears are used for parallel shaft drives. They have enamel inclined to the axis as proven in fig. 1.

For this reason for the identical width, their teeth are longer than spur gears and have better load supporting

capacity. their touch ratio is higher than spur gears and that they operate smoother and quieter than spur gears.

Their precision rating is ideal. they're recommended for extremely high speeds and masses. Hence, these gears

discover extensive packages in car gearboxes as illustrated in fig.Their performance is barely decrease than spur

gears. the helix perspective additionally introduces axial thrust on the shaft.

Fig:2.1 Helical Gear

In mechanical engineering, a helix angle is the angle between any helix and an axial line on its right,

circular cylinder or cone. Common applications are screws, helical gears, and worm gears. the helix angle

references the axis of the cylinder, distinguishing it from the lead angle, which references a line perpendicular to

the axis. clearly, the helix angle is the geometric supplement of the lead perspective. the helix attitude is

measured in levels.

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 Fig: 2.1.1 Helix angle

2.2 CONCEPT

In terms specific to screws, the helix angle can be located via unraveling the helix from the screw, representing
the phase as a right triangle, and calculating the perspective this is fashioned. note that while the terminology
directly refers to screws, those ideas are analogous to maximum mechanical programs of the helix altitude

The helix angle can be expressed as:

Where

8
 l is lead of the screw or gear
rm is mean radius of the screw thread or gear

2.2.1 Helical Gear Characteristics:

Helix angle 7 to 23 degrees

 More power More power 
 Larger speeds More smooth and quiet operation 

 Used in automobiles 
 Helix angle must be the same for both the mating 

Produces axial thrust which is a disadvantage

9
2.3 Helical Gears Geometry and Nomenclature:

The helix angle ψ, is always measured on the cylindrical pitch surface. ψ value is not standardized. It

ranges between 150 and 450 . Commonly used values are 15, 23, 30 or 45deg . Lower values give less end thrust.

Higher values result in smoother operation and more end thrust. Above 45degrees is not recommended.

Fig: 2.3 Portion of a helical rack

The circular pitch (p) and pressure angle (α) are measured in the plane of rotation, as in spur gears.

These quantities in normal plane are denoted by suffix n (pn , αn ) as shown in Fig.

pn = p cos ψ

Normal module mn

mn = m cos ψ mn is used for hob selection.

The pitch diameter (d) of the helical gear is: d = Z m= Z mn / cos ψ.

The axial pitch (pa ) is: pa = p / tan ψ

For axial overlap of adjacent teeth, b ≥ pa (3.5) In practice b = (1.15 ~2) pa is used. In the case of a helical
gear, the resultant load between mating teeth is always perpendicular to the tooth surface. Hence bending
stresses are computed in the normal plane, and the strength of the tooth as a cantilever beam depends on its
profile in the normal plane. Fig shows the view of helical gear in normal and transverse plane. Fig. shows the
pitch cylinder and one tooth of a helical gear. The normal plane intersects the pitch cylinder in an ellipse. If d

10
is the pitch diameter of the helical gear, the major and minor axes of the ellipse will be d/cos ψ and d. The
radius of curvature Re at the extremes of minor axis from coordinate geometry is found to be d/(2 cos2 ψ).

Fig: 2.3 View of helical gear in normal and transverse section

The shape of the tooth in the normal plane is nearly the same as the shape of a spur gear tooth having a pitch

radius equal to radius Re of the ellipse.

Re = d/(2cos2 ψ)

The equivalent number of teeth (also called virtual number of teeth), , is defined as the number of teeth in a gear

of radius Re :Zv = 2Re /mn = d/ mncos2ƒ

Substituting mn = m cosψ, and d = Z m Zv = Z cos3ƒ

When we compute the bending strength of helical teeth, values of the Lewis form factor Y are the same as for

spur gears having the same number of teeth as the virtual number of teeth (Zv ) in the Helical gear and a pressure

angle equal to αn . Determination of geometry factor J is also based on the virtual number of teeth.

Fn = Ft cos α n cos +tan αn = tanα.cos ψ

11
 Fig 2.3 :Tooth force and its components acting on a right hand helical gear

2.3.1 Helical Gears- Tooth Proportions:

In helical gears, the normal module mn should be selected from standard values, the first preference values are

mn (in mm) = 1, 1.25, 1.5, 2, 2.5, 3, 4, 5,6, 8 and 10 The standard proportions of addendum and dedendum are

ha = mm , hf = 1.25 mm , c = 0.25 mm The addendum and dedendum circle diameters are given respectively;

da = do + 2Ma = mn(( Z/ cos ƒ) + 2) d† = do − 2M† = mn( Z cos ƒ − 2. 5)

The normal pressure angle, αn is generally 20degrees

and the face width b is kept as

b ≥ g mn/sin †

2.3.2 Helical Gears - Force Analysis:

Fr = Fn sin αn
Ft = Fn cos αn cos ψ

Fa = Fn cos αn sin ψ

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 Fr = Ft tan α

Fa = Ft tan ψ

2.3.3 Helical Gears- Bending Strength:

Beam Strength of a helical gear normal plane is considered equivalent to that of a spur gear in

tangential plane. Spur gear: beam strength, Sb = m b σb Υ

Helical gear: beam strength, (Sb )n = mn bn σb Υn

Or

(Sb )n = mn (b/ cos † ) obYn

But Sb is the component of (Sb )n in the plane of rotation, i.e.,

Sb = (Sb )n cos ψ

Sb = mn b σb Υn

where Υn will be calculated for Z/cos3 ψ number of teeth.

Beam strength Sb indicates the maximum value of tangential force that the tooth can transmit without bending

failure.

2.4 Advantages of Helical gear

13
 As we know that in case of helical gear ,engagement of helical gear teeth will start from one end

to a tooth of helical gear with other tooth of mating helical gear and spread continuously

throughout the tooth as gear rotates. such gradual engagement of helical gear will provide the

silent and smooth operation

 Helical gears are preferred for heavy load applications

 Helical gears could be used to produce transmit power between two parallel shafts and also

between two non parallel shafts

 There will we less wear and tear in case of helical gear during operation as compared to wear and

tear in case in case spur gear operation as if we consider helical operation, load will be distributed

between several teeth at any time and that is why there will be less war and tear in operation of

helical gear

 Helical gear will have more capability to transmit load between two parallel shafts as compared to

similar module and equivalent width of spur gears

2.5 Disadvantage of Helical Gear

 When a pair of helical gear meshes with each other, there will be certain of axial thrust load on

gear due to helix angle of gear teeth and therefore gear box designer has to select such bearings

those are able to absorb and support axial thrust load.

 There will be sliding movement between mating gear teeth in case of helical gear and heat

generation will be more as compared to spur gear application. Therefore helical gear requires

good quality of lubrication.

 One pair of mating helical gear will have less efficiency as compared to efficiency of mating

14
 spur gears of similar size.

 Power loss in case of helical gear train operation will be more as compared to spur gear train

operation.

 Manufacturing and designing cost of helical gears will be more as compared to spur gear.

2.6 Applications of helical gears

Helical gears are normally preferred to work under heavy load efficiently. When we need silent

operations such as in automobile applications, we prefer to use helical gears as such gears work

silently and smoothly.

 Helical gears are used in fertilizer industries, printing industries and earth moving industries

 Helical gears are also used in steel, rolling mills, section rolling mills, power and port industries.

 Helical gears are also used in textile industries, plastic industries, food industries, conveyors,

elevators, blowers, compressors, oil industries and cutters.

2.7 TYPE OF MATERIALS USED

Depending on some advantages and for comparison purpose we have selected “SCM440, S45C,
15
Structural Steel” materials.

2.7.1 SCM440(Chrome –molybdenum alloy steel)

An alloy steel containing moderate amounts of carbon(0.40%).

It also contains chrome/molybdenum.

SCM440 has more strength than S45C and is used with thermal-refining induction hardening
treatment for producing gears

2.7.2 Chemical composition of JIS SCM440

 Carbon 0.38 to 0.7%

 Copper 0.3%

 Molybednum0.15-0.3%

 Silicon 0.15-0.35%

 Manganese 0.6-0.85%

 Chromium 0.9-1.2%

 Nickel 0.25% and other remaining

2.7.3 MECHANICAL PROPERTIES OF JIS SCM440

 Yield strength >830N/mm2

16
  Tensile strength >830N/mm2

 %of elongation-12%

 It has better tensile strength than chromium steels

 It has good strength and toughness

Characteristics, heat treatments applied:

Medium-carbon alloy steel(C content:0.3-0.7%).

Thermal refined and induction hardened(High strength/High surface durability).

Used in gear manufacturing, except in worm wheels

Table 2.7.4 Heat Treatment and Hardness

2.8 JIS S45C MATERIAL

Heat Treatment Hardness

Thermal refining 225-206HB

Induction Hardening 45-55HRC

JIS SCM45C grade carbon steel is widely used in machinery manufacturing,It is a medium strength steel

suitable for shafts, keys etc It is easily obtainable and used in production of spur, helical, bevel and worm

gears.

2.8.1 CHEMICAL COMPOSITION OF JIS S45C:

17
  Carbon 0.42-0.48%

 Manganese 0.60-0.90%

 Silicon others 0.15-0.35% and remaining

2.8.2 MECHANICAL PROPERTIES OF JIS S45C

 Density 7700-8030kg/m3

 Young’s Modulus 190-210Gpa

 Tensile Strength 569 Mpa

 Yield Strength 343Mpa

 Poisson’s ratio 0.27-0.30

2.8.3 Table Heat Treatment and Hardness

Heat Treatment Hardness

None Less than 194HB

Thermal Refining 225-260HB

Induction Hardening 45-55HRC

2.8.4 THERMAL REFINING

Thermal refining is a heat treatment applied to adjust hardness/strength/toughness of steel.This treatment
18
involves quenching and high temperature tempering, in combination. After thermal refining is performed ,the

hardness is adjusted by these treatments to increase the metals machinable process

2.8.5 INDUCTION HARDENING

Induction hardening is a heat treatment performed to harden the surface by induction-heating of steel, composed

of 0.3%carbon.For gear products, Induction hardening is effective for hardening toot areas including tooth

surface and the tip, However the root may not be hardened in some cases, Generally, The precision of gears

declines from deformation caused by induction hardening .

2.9 Structural Steel

Structural steel is a category of steel used for making construction materials in variety of shapes .Structural steel

shapes, sizes, chemical composition, mechanical properties etc, are regulated by standards in most industrialized

countries.

Usually yield strength of steel structure increases around 5% over stress relieved strain and steel structure would

suffer from plastic elongation with around 0.01.

19
 Chapter III

3. Literature Review

This research attempts to review literatures, which are relevance to analysis gear of stresses Isay and Fong [2]

applied the tooth contact analysis technique (TCA) and finite element method (FEM) to gear contact and stress

analysis. In their study, a mathematical model for pinion and gear involutes teeth is assumed. The geometry of

the gears are described by parameters of manufacturing. Computer simulations of the conditions of gear

meshing including the axes misalignment and center distance variation are performed. Their paper showed that

the locations of total deformation and strain pattern of mating tooth surfaces are determined by TCA techniques.

The results of the TCA provide the location and the direction of applied loads for the computer aided FEM stress

analysis,by applying the given mathematical model and TCA techniques. A three-dimensional stress analysis for

this type of gearing was investigated by Von-Mises stress contour distribution. Vljayaragan and Ganesan [4]

presented a static analysis of composite helical gears system using three dimensional finite element methods to

study the displacements and stresses at various points on a helical gear tooth. The validity of their results of the

FEM was tested by the root stress for scm440 material gear and comparing the result with obtained from

conventional gear design equation. The paper presented also the evaluation of the performance of composite

helical gears by companion of with that of the conventional carbon steel gear. It is observed form the result that

20
composite materials can be used safely for power transmission helical gears but the face width has to be suitably

increased.

CHAPTER IV
4 Project Schedule

Title Decided 19th December 2017

27th December 2017 Abstract Submitted

Initial Design modelling finished 9th January 2018

21
 21st January 2018 Designs finalised using solid works

Material selection finished for analysis purpose 18th February 2018

Analysis done for two materials

25thFebruary

Comparing the third material with the analysis

done for the two materials 24th February 2018

16th March 2018 Choosing the best material

Project Submission Internal Exam 27th March

3rd April Project Submission External Exam

22
 CHAPTER V

5.1 Designing of helical gear Introduction To Solid Works:

Solid works mechanical design automation software is a feature-based, parametric solid

modeling design tool which advantage of the easy to learn windows TM graphical user

interface. We can create fully associate 3-D solid models with or without while utilizing

automatic or user defined relations to capture design intent.

General Procedures to Create an Involute Curve

The sequence of procedures employed to generate the involute curve are illustrated as

follows: -

1. Set up the geometric parameters

 Number of teeth

 Diametral Pitch

 Pressure angle

 Pitch diameter

 Face width

 Helix angle

2. Create the basic geometry such as addendum, dedendum and pitch circles in

support of the gear tooth.

23
 3. Define the involute tooth profile with datum curve by equation using cylindrical

coordinate system.

4. Create the tooth solid feature with a cut and extrusion. Additional helical datum

curves are also required in this step to sweep helical gear teeth.

5. Pattern the tooth around the centre line axis.

Modeling of helical gear is started with drawing the reference sketch for the gear radius and tooth profile.

Fig 5.1: Modeling of Helical Gear

After generating the sketches go through the sweep feature

5.2 Initial Design of Helical Gear

24
Fig 5.2:Initial Design of Helical Gear

25
 5.3 Desing of helical gear is completed in solid works with number of teeths=20 and

Helix Angle 21.5

Fig 5.3.1: Design of helical gear with teeth 20 and helix angle 21.5

The key specifications of geometrical parameters and the helical gear model developed by

using the above procedures in Solid works are shown in and Table respectively .

Table key 5.3.1 geometrical parameters of helical gear used

Number of teeth 20
Diameteral pitch ( p) 280
[mm]
Total Depth 47
Face width [mm] 80
Addendum [mm] 1/p
Dedendum [mm] 1.25/p
Helix angle 21.5
300
Outer Diameter[mm]
33.8
CircularThickness [mm]

26
5.3.2 Desing of helical gear is completed in solid works with number of teeths=20 and

Helix Angle 15

Fig 5.3.2: Design of helical gear with teeth 20 and helix angle 15

Table key 5.3.2: geometrical parameters of helical gear used

Number of teeth 20
Diameteral pitch ( p) 124.331
[mm]
Total Depth 27
Face width [mm] 40
Addendum [mm] 1/p
Dedendum [mm] 1.25/p
Helix angle 15
Outer 136.340
Diameter[mm]

CircularThickness[mm] 26.864

27
 CHAPTER VI

ANSYS is the name commonly used for ANSYS mechanical, general-purpose finite element

analysis (FEA) computer aided engineering software tools developed by ANSYS Inc. ANSYS

mechanical is a self contained analysis tool incorporating pre-processing such as creation of

geometry and meshing, solver and post processing modules in a unified graphical user
interface.

ANSYS is a general-purpose finite element-modeling package for numerically solving

a wide variety of mechanical and other engineering problems. These problems include linear

structural contact analysis that is non-linear. Among the various FEM packages, in this work

ANSYS is used to perform the analysis

The following steps are used in the solution procedure using ANSYS

1. The geometry of the gear to be analyzed is imported from solid works in IGES format this

is compatible with the ANSYS.

2. The element type and materials properties such as Young's modulus and Poisson's ratio

are specified.

3. Meshing the three-dimensional gear model. Figure 4.2 shows the meshed 3D solid model

of gear.

4. The boundary conditions and external loads are applied.

5. The solution is generated based on the previous input parameters.

6. Finally, the solution is viewed in a variety of displays.

28
 6.1 Static Load Analysis on different type of materials

We will perform 4 different analysis like Equivalent stress, Total Deformation,Maximum shear

strain and fatigue load on three different materials with changing gear helix angle and comparing those results.

6.1.1 Static S.No Loading Condition Moment(N/ Load Analysis

mm)
1 Face of gear 50
The following test cases and loading

conditions were considered for performing the static load analysis.

This analysis was carried out using ANSYS 18.2 in the Static Load condition.

Table 6.1: Loading Conditions for Static Load Analysis

29
6.1.2 Equivalent stress Analysis( For helical gear of teeth 20 and helix angle21.50)

The Equivalent stress is widely used to check whether the design will withstand a given load

conditions.From von mises stress analysis we can know the maximum and minimum stress induced in different

materials for a helical gear .

Results

For Helical gear with Teeth 20 with helix angle 21.5(Material S45C)

Fig6.1.2: Equvivalent stress for helical gear of material S45C

Table: 6.1.2 Equivalent Stress ( Von Mises Stress )

S.No Analytical Observation

1 Moment 50N/mm
2 Maximum Stress 1.3474e8Pa
3 Minimum Stress 85395Pa

30
 Inference: The result obtained from ANSYS WORKBENCH 18.2 show that the global

value of maximum stress is 1.3474e8Pa,which is in range as per our design calculations. The occurrence of the

maximum stress along the helical teeth justifies that our design criteria is correct according to the design

principles used.

6.1.3 Material SCM440( For helical gear of teeth 20 and helix angle21.50)

Fig6.1.3: Equivalent stress for helical gear of material SCM440

Table: 6.1.3 Equivalent Stress ( Von Mises Stress )

S.No Analytical
Observation
1 Moment 50N/mm
2 Maximum Stress 1.3597e8Pa
3 Minimum Stress 84903Pa

31
 Inference: The result obtained from ANSYS WORKBENCH 18.2 show that the global value of

maximum stress is 1.3597e8Pa,which is in range as per our design calculations. The occurrence of the maximum

stress a long the helical teeth justifies that our design criteria is correct according to the design principles used.

6.1.4 Material Structural steel( For helical gear of teeth 20 and helix angle21.50)

Fig 6.1.4:Equivalent Stress for Structral steel

Table: 6.1.4 Equivalent Stress ( Von Mises Stress)

S.No Analytical Observation

1 Moment 50N/mm
2 Maximum Stress 1.3474e8Pa
3 Minimum Stress 85396Pa

Inference: The result obtained from ANSYS WORKBENCH 18.2 show that the global value of

maximum stress is 1.3474e8Pa,which is in range as per our design calculations. The occurrence of the

32
maximum stress along the helical teeth justifies that our design criteria is correct according to the design

principles used.

6.2 Total Deformation Analysis(For helical gear of teeth 20 and helix angle21.50)

Here we will study the total deformation in all the 3directions to know the maximum and minimum
Deformation for three different materials.

Results

For Helical Gear with teeth 20 and Helix angle 21.5

Fig 6.2.1: Total Deformation for helical gear of S45C

Table:6.2.1 Total Deformation S45C

S.No Analytical Observation

1 Moment 50N/mm
2 Maximum 1.8784e-5(m)
3 Minimum 4.8413e-6(m)

33
 Inference: The result obtained from ANSYS WORKBENCH 18.2 show that the global value of

maximum deformation is 1.8784e-5,which is in range as per our design calculations. The occurrence of the

maximum deformation at the helical gear justifies that our design criteria is not good according to the design

principle used compare to other material.

6.2.2.Material SCM440(For helical gear of teeth 20 and helix angle21.50)

Fig 6.2.2: Total Deformation of Helical Gear for SCM440

Table: 6.2.2 Total Deformation for SCM440

S.No Analytical Observation

1 Moment 50N/mm
2 Maximum Stress 2.0694e- 5(m)
3 Minimum Stress 5.3382e-005(m)

34
 Inference: The result obtained from ANSYS WORKBENCH 18.2 show that the global value of

maximum deformation is2.0694e-5,which is in range as per our design calculations. The occurrence of the

maximum deformation at the helical gear justifies that our design criteria is good according to the design

principle used for SCM440.

6.2.3.Material Structural Steel (For helical gear of teeth 20 and helix angle21.5 0)

Fig 6.2.3 Total Deformation of structural steel

35
 Table: 6.2.3 Total Deformation for Structural Steel

S.No Analytical Observation

1 Moment 50N/mm
2 Maximum 1.9723e-
5(m)
3 Minimum 5.0833e-
6(m)

Inference: The result obtained from ANSYS WORKBENCH 18.2 show that the global value of

maximum deformation is1.9723e-5,which is in range as per our design calculations. The occurrence of

the maximum deformation at the helical gear justifies that our design criteria is good according to the design

principle used for Structural steel.

36
6.3 Maximum shear elastic strain Analysis (For helical gear of teeth 20 and helix angle21.50)

Here we are observing the Maximum and Minimum shear elastic strain for three materials different
Material

Results

6.3.1 Material S45C ( For helical gear of teeth 20 and helix angle21.50)

Fig 6.3.1: Maximum shear elastic strain for S45C

Table: 6.3.1 Maximum shear elastic strain for S45C

S.No Analytical Observation

1 Moment 50N/mm
2 Maximum 9.3305e-004(m/m)
3 Minimum 5.9544e-007(m/m)

37
 Inference: The result obtained from ANSYS WORKBENCH 18.2 show that the global value of

maximum shear elastic strain is 9.3305e-004,which is in range as per our design calculations. The occurrence of

the maximum shear elastic strain at the helical gear justifies that our design criteria is not good according to the

design principle used for S45C.

6.3. 2 Material SCM440(for helical gear of teeth 20 and helix angle21.50)

Fig 6.3.2:Maximum shear elastic stain for SCM440

Table: 6.3.2 Maximum shear elastic strain for SCM440

S.No Analytical Observation

38
 1 Moment 50N/mm
2 Maximum 1.0303e-003(m/m)
3 Minimum 6.4798e-007(m/m)

Inference: The result obtained from ANSYS WORKBENCH 18.2 show that the global value of maximum

Shear elastic strain 1.0303e-3,which is in range as per our design calculations. The occurrence of the

maximum shear elastic strain at the helical gear justifies that our design criteria is good according to the

design principle used for SCM440.

6.3.3 Material Structural Steel (for helical gear of teeth 20 and helix angle21.5)

39
 Fig 6.3.3:Maximum shear elastic strain for Structural steel

Table: 6.3.3 Maximum shear elastic strain for structural steel

S.No Analytical Observation

1 Moment 50N/mm
2 Maximum 9.797e-004(m/m)
3 Minimum 6.2522e-007(m/m)

Inference: The result obtained from ANSYS WORKBENCH 18.2 show that the global value of max

shear elastic strain is 9.797 e-004,which is in range as per our design calculations. The occurrence of the

maximum shear elastic strain at the helical gear justifies that our design criteria is good according to the

design principle used for Structural steel.

40
 6.4 Fatigue load Analysis

Fatigue is the failure of material structure due to crack initiation and development under the influence of cyclic

loading we will perform fatigue analysis under static load condition to know the behavior of material.

6.4.1 Material S45C (for helical gear of teeth 20 and helix angle21.50)

RESULT

41
 6.4.2 Material SCM440(For helical gear of teeth 20 and helix angle21.50)

6.4.3 Material Structural Steel (For helical gear of teeth 20 and helix angle21.50)

42
 6.5 Result and Discussion

Table of Results 6.5

Material Deformation(mm)

SCM440 2.0694e-005

S45C 1.8784e-005

Structural Steel 2.9723e-005

 Helical gear is designed by using various commands in solid works

43
  Static analysis is done on helical gear in solid works simulation tool

 Different materials at different loads are applied and stress, strain and displacement values are analyzed

 The stress, strain and displacement values for different materials at different loads are noted and tabulated

From the results SCM440 and Structural steel are more preferable when compared to S45C because at a given

Moment its showing deformation.

44
6.6 Static Analysis (For helical gear of teeth 20 and helix angle 15)

6.6.1 -a)Equivalent Stress Analysis (For helical gear of teeth 20 and helix angle 15)

Equivalent stress for S45C

Table: Equivalent Stress 6.6.1 ( Von Mises Stress )

S.No Analytical Observation

1 Moment 50N/mm
2 Maximum Stress 1.4977e8Pa
3 Minimum Stress 421712

Inference: The result obtained from ANSYS WORKBENCH 18.2 show that the global value of maximum

Stress is 1.4977e8Pa,which is in range as per our design calculations. The occurrence of the maximumstress

Along the helical teeth justifies that our design criteria is correct according to the design principles used
45
but compare to other material S45C in not preferable.

6.6.2 Material SCM440(for helical gear of teeth 20 and helix angle 15)

Fig 6.6.2:Equivalent stress for scm440

Table: 6.6.2 Equivalent Stress ( Von Mises Stress ) (Material SCM440)

S.No Analytical Observation

1 Moment 50N/mm
2 Maximum Stress 1.5089e8Pa
3 Minimum Stress 40059Pa

46
 Inference: The result obtained from ANSYS WORKBENCH 18.2 show that the global value of maximum

stress is 1.5089e8Pa,which is in range as per our design calculations. The occurrence of the maximumstress

along the helical teeth justifies that our design criteria is correct according to the design principles used.

6.6.3.Material Structural Steel(For helical gear of teeth 20 and helix angle 15)

Fig 6.6.3 Equivalent stress for structural steel

47
 Table: 6.6.3 Equivalent Stress ( Von Mises Stress ) (Material SCM440)

S.No Analytical Observation

1 Moment 50N/mm
2 Maximum Stress 1.347e8Pa
3 Minimum Stress 85396Pa

Inference: The result obtained from ANSYS WORKBENCH 18.2 show that the global value of maximum

stress is 1.3474e8Pa,which is in range as per our design calculations. The occurrence of the maximumstress

along the helical teeth justifies that our design criteria is correct according to the design principles used.

6.7 a )Total Deformation Analysis(Helical gear teeth 20 with helix angle 15)

S.No Analytical Observation

1 Moment 50N/mm
2 Maximum 1.9178e-5(m)
3 Minimum 3.9621e-6 (m) Fig 6.7 Total
Deformation for S45C

Table :6.7 Total Deformation for S45C

48
 Inference: The result obtained from ANSYS WORKBENCH 18.2 show that the glob value of maximum

deformation is 1.9178e8Pa,which is in range as per our design calculations. The occurrence of the max

deformation along the helical teeth justifies that our design criteria is not correct according to the design

principles used. compare with other materials.

6.7.1 Material SCM440( Helical gear teeth 20 with helix angle 15)

Fig 6.7.1:Total deformation of SCM440

Table :6.7.1 Total Deformation for SCM440

49
 S.No Analytical Observation
1 Moment 50N/mm
2 Maximum 2.171e-5(m)
3 Minimum 4.367e-6 (m)

Inference: The result obtained from ANSYS WORKBENCH 18.2 show that the global value of maximum

deformation is 2.171e-5 m,which is in range as per our design calculations. The occurrence of the max

deformation Along the helical teeth justifies that our design criteria is correct according to the design

principles used,compare with other materials.

6.7.2 Material Structural Steel( Helical gear teeth 20 with helix angle 15)

50
 Table 6.7.2 Total Deformation for S45C

S.No Analytical Observation

1 Moment 50N/mm
2 Maximum 1.9723e-5(m)
3 Minimum 50833e-6 (m)

Inference: The result obtained from ANSYS WORKBENCH 18.2 show that the global value of maximum

deformation is 1.9723e-5 m,which is in range as per our design calculations. The occurrence of the max

deformation Along the helical teeth justifies that our design criteria is correct according to the design

principles used,compare with other materials.

6.8 -a)Maximum Shear Elastic Strain Analysis(Helical gear teeth 20 with Helix angle 15)

51
 Fig 6.8:Maximum shear elastic strain(Material S45C)

Table 6.8 Maximum shear elastic strain for S45C

S.No Analytical Observation

1 Moment 50N/mm
2 Maximum 0.00105565(m/m)
3 Minimum 2.8348e-7(m/m)

Inference: The result obtained from ANSYS WORKBENCH 18.2 show that the glob value of maximum

shear elastic strain is 0.00105565 m/m, which is in range as per our design calculations. The occurrence of

max shear elastic strain along the helical teeth justifies that our design criteria is correct according to the

design principle used.

6.8.1 Material SCM440( Helical gear teeth 20 with helix angle 150)

52
 Fig 6.8.1:Maximum shear elastic strain(Material SCM440)

Table 6.8.1 Maximum shear elastic strain for SCM440

Inference: The result obtained from ANSYS WORKBENCH 18.2 show that the glob value of maximum

shear elastic strain is 0.0011667 m/m, which is in range as per our design calculations. The occurrence of

max shear elastic strain along the helical teeth justifies that our design criteria is correct according to the

design principle used.

S.No Analytical Observation
1 Moment 50N/mm
6.8.2 2 Maximum 0.0011667(m/m) Material Structural
steel ( Helical gear 3 Minimum 2.9696e-7(m/m) teeth 20 with helix
angle 150)

53
 Fig 6.8.1:Maximum shear elastic strain Structural Steel

Table 6.8.2 Maximum shear elastic strain for Structural steel

S.No Analytical Observation

1 Moment 50N/mm
2 Maximum 0.0009797(m/m)
3 Minimum 6.2522e-7(m/m)

Inference: The result obtained from ANSYS WORKBENCH 18.2 show that the glob value of maximum

shear elastic strain is 0.0009797 m/m, which is in range as per our design calculations. The occurrence of

max shear elastic strain along the helical teeth justifies that our design criteria is correct according to the

design principle used.

54
 6.9 -a) Fatigue Load(Material S45C) ( Helical gear teeth 20 with helix angle 150)

6.9.1 Material SCM440( Helical gear teeth 20 with helix angle 150)

55
6.9.2 Material Structural Steel( Helical gear teeth 20 with helix angle 150)

56
57
 CHAPTER VII

7.1 RESULT AND DISCUSSIONS

7.1.1 Result Table

Material Number of Moment Helix Total Deformation Helix Total

teeth (N/mm) angle angle Deformation

SCM440 20 50 15 2.171e-005 21.5 2.0694e-005

S45C 20 50 15 1.9718e-005 21.5 1.8748e-005

Structural 20 50 15 2.0704e-005 21.5 1.9723e-005

Steel

By changing helix angle we will compare which is better for gear tooth of 20. Helical gears make the operation

gearing smooth. In helical gear contact of gear and pinion teeth would be gradual,unlike the spur gears .Increasing

helix angle will make gear smooth but increase axial load,so it can have negative effect on transmission. Power

loss is still present and with increasing helix angle it will continue to go high so reducing helix angle

is better compared to increase in some conditions.So from our analysis,the gears with helix angle 15 are better for the

materials on which we performed analysis.

58
 CHAPTER VIII

8.1 Future work

Analytical method of gear analysis uses a number of assumptions and simplifications and it is intended to

determine the maximum stress values. In this paper, numerical approach has used for predicting the static

equivalent stress ,strain and total deformation of involute helical gear. A parametric study is also made by

varying the helix angle to investigate their effect on the helical gears. The contribution of this thesis work can be

summarized as follows:

 The strength of the gear tooth is a crucial parameter to prevent failure. In this study, it is
shown that the effective method to estimate the total deformation using three dimensional
model of the gear and to verify the accuracy of this method the results with different number
of teeth are compared with the standard formula.

 Here we will study which material is best after performimg static analysis on each material
and by changing helix angle.

Based on result we could select best one for recommendation and future work.
The thesis paper can be an interest for researchers, instructors and postgraduate students who
have great enthusiasm to work more on gears. It may give enlightenment about the
characteristics of involute helical gears and evoke pervious works of various bodies that are
involved in gears research and production. Further more this study contribute to a better gear
design, assist technological institutions and all those who are interested in invloute helical
gears. More work can be done to improve this study and to obtain better output. Generally, the
following areas are worthy for further research in the light of this thesis.

 Further three dimensional numerical method of investigation and study can be conducted on
the analysis of static analysis for all types of gears such as spur, bevel and other tooth forms.

 Further numerical method of investigation and study can be conducted on the whole gearbox
with all elements in the system including gear casing and bearing.

59
 Further numerical method of investigation and study can be conducted on gears in mesh under
dynamic condition with and with out cracked teeth, surface pitting or wear.

 The static analysis of gears made of different materials using three-dimensional finite element
analysis can be recommended as future work.

CHAPTER IX
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