Government Engineering College Rajkot: Gujarat Technological University

GUJARAT TECHNOLOGICAL UNIVERSITY
Chandkheda, Ahmedabad Affiliated
Government Engineering College

Rajkot
TO STUDY THE EFFECT OF CARURIZING AND NITRIDING

PROCESS ON LOSSES IN HELICAL GEAR PAIR.
In partial fulfillment of the award of the degree of
BACHELOR OF ENGINEERING
In
AUTOMOBILE ENGINEERING
Semester - 7
Submitted by:
Group ID: - 58148

Sr. No. Name Of Student Enrollment
1 Gothi Mahek D. 160200102021
2 Naik Jay N. 160200102032
3 Patel Priyavadan A. 160200102038
4 Prajapati Dhruv C. 160200102040
Prof. U.R.BHUVA (AUTOMOBILE)

Internal Guide
Prof. K.D.CHAUDHARI (AUTOMOBILE)

Head of Department
1
Academic year (2019-20)

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TO STUDY THE EFFECT OF CARURIZING AND NITRIDING PROCESS ON LOSSES IN HELICAL GEAR PAIR.
GOVERNMENT ENGINEERING
COLLEGE RAJKOT
CERTIFICATE
This is to certify that the project report entitled “to study the effect
of carburizing and nitriding process on losses in helical gear pair” has
been carried out by Gothi Mahek (160200102021) under my guidance in
partial fulfilment of the degree of bachelor of engineering in automobile
engineering (7th semester) of Gujarat Technological university;
Ahmedabad during the academic year 2019-20.
Date:-
Internal Guide: Head of the Department
Prof. U.R.Bhuva Asst. Prof. K.D.Chaudhari
Automobile Department Automobile Department
G.E.C. Rajkot G.E.C. Rajkot

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External Examiner:
COLLEGE RAJKOT
CERTIFICATE
been carried out by Naik Jay (160200102032) under my guidance in
partial fulfilment of the degree of bachelor of engineering in automobile
Date:-

3
Page
External Examiner:
COLLEGE RAJKOT
CERTIFICATE
been carried out by Patel Priyavadan (160200102038) under my guidance
in partial fulfilment of the degree of bachelor of engineering in automobile
Date:-

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Page
External Examiner:
COLLEGE RAJKOT
CERTIFICATE
been carried out by Prajapati Dhruv (160200102040) under my guidance
in partial fulfilment of the degree of bachelor of engineering in automobile
Date:-

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External Examiner:
ACKNOWLEDGEMENT
We have taken many efforts in this project. However, it

would not have been possible without the kind support and help
of many individuals and organizations. We would like to extend
my sincere thanks to all of them.
We are highly indebted to “Prof. U.R.BHUVA” for their

guidance and constant supervision as well as for providing
necessary information regarding the Design Engineering Project
Titled “To Study the Effect of Carburizing and Nitriding Process
on Losses in Helical Gear Pair”.
We even thank and appreciate to our colleague in developing

the project and people who have willingly helped us out with their
abilities such as “Prof. D.J.Marsoniya”.
Mahek Gothi
Naik.Jay.N
Patel Priyavadan
Prajapati Dhruv
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ABSTRACT
To Design A Helical Gear And Its Analysis And Used Of

Helical Gear In Transmission System. Transmission System Are
Although Highly Efficient But There Are Some Small Losses
Due To Churn Of Lubricant. To Study About Carburizing And
Nitriding Heat Treatment Process On Load Independent Power
Losses In Helical Gear And Also About Churning
Losses,Windage Losses, Pocketing Losses And Surface
Roughness And To Study About Effect Of Heat Treatment
Processes On Power Losses And Efficiency Of Transmission
System.
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TABLE OF CONTENT
SR. INDEX PAGE
NO. NO.
1 INTRODUCTION 12
1.1 DEFINATION 12
1.2 OBJECTIVES 13
1.3 PROBLEM STATEMENT 13
1.4 HEAT TREATMENT PROCESS 16
1.4.1 CARBURAIZING HEAT TREATMENT 17
PROCESS
1.4.2 NITIDING HEAT TREATMENT PROCESS 18
2 LITERATURE REVIEW 20
2.1 J.OLLY, DAVID TALBOT, AHMET 20
KAHRAMAN, AVINASH SINGH, HAI XU
2.2 Yasutsune ARIURA, Taku UENO, Teruo SUNAGA, 21
Shigemi SUNAMOTO
2.3 PatrickAlbers, C. Changenet, Dr. P.A. Veenhuizen 22
2.4 Joseph H. Polly 23
2.5 Satya Seetha Raman 24
2.6 A.Y Gidado, I. Muhammad, A. A. Umar 26
2.7 K. NARESH, C. CHANDRUDHU 27
2.8 MALLA MAHESH , Dr. S RAMAKRISHNA 27
3 DESIGN AND SPECIFICATION 29
3.1 GEAR TERMINOLOGY 29
3.1.1 FIGURE SHOWS THE TERMINOLOGY 29
RELATED TO GEAR:
3.2 DESIGN OF HELICAL GEAR FOR DIFFERENT 30
HELIX ANGLE
3.2.1 CACULATION OF GEAR TERMINOLOGY 30
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3.2.2 CALCULATION OF LOAD AND STRES 36
4 BEAM STRENGTH ANALYSIS OF HELICAL GEAR 40
4.1 ANALYSIS OF HELICAL GEAR FOR 40
DIFFERENT HELIX ANGLE
4.1.1 ANALYSIS FOR GEAR WITH HELIX ANGLE 41
IS 20 DEGREE.
IS 22 DEGREE.
IS 24 DEGREE.
IS 26 DEGREE.
IS 28 DEGREE.
IS 30 DEGREE.
4.2 ANALYSIS OF HELICAL GEAR FOR 47
DIFFERENT MATERIAL
4.2.1 ANALYSIS FOR GEAR WITH MATERIAL IS 46
GREY CAST IRON
STRUCTURAL STEEL
CAST STEEL
MAGNESIUM ALLOY
5 CONCLUSION 55
6 PLANNING FOR NEXT PHASE 56
7 REFERNCES 57
9
8 APPENDIX-A 59
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List of Symbols:
Sr. Gear Terminology Symbol
No.
1 Helix Angle α
2 Transverse Module mt
3 Normal Module mn
4 Pitch Circle Diameter PCD
5 Number Of Teeth Z
6 Pressure Angle Ø
7 Normal Pressure Angle Øn
8 Transverse Circular Pitch Ptc
9 Normal Circular Pitch Pnc
10 Transverse Diametral Pitch Ptd
11 Normal Diametral Pitch Pnd
12 Addendum Ha
13 Dedendum Hf
14 Addendum Circle Diameter DHa
15 Dedendum Circle Diameter DHf
16 Base Circle Diameter Db
17 Axial Pitch Pa
18 Tooth Face Width b
19 Equivalent Number Of Teeth TE
20 Pitch Line Velocity V
21 Velocity Factor CV
22 Lewi’s Form Factor Y
23 Transmitted Torque MT
24 Tangential Load WT
25 End Trust On The Gear WA
26 Beam Strength Sb
10
27 Static Stress
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List of Figure :
Sr. Figure Page
no. number
1 FIGURE [01]: EXPERIMENTAL SETUP 24
2 FIGURE [02]: GEAR TERMINOLOGY (a) 29
3 FIGURE [03]: GEAR TERMINOLOGY(b) 30
4 FIGURE [04]: SOLID WORKS MODEL 35
5 FIGURE [05]: Von Mises Stress for Helix 41
Angle 20
Angle 22
Angle 24
Angle 26
Angle 28
Angle 30
11 FIGURE [11]: Von Mises Stress for Grey 48
Cast Iron
12 FIGURE [12]: Von Mises Stress for 50
Structural Steel
13 FIGURE [13]: Von Mises Stress for Cast 52
Steel
14 FIGURE [14]: Von Mises Stress for 54
Magnesium Alloy
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CHAPTER 1.
INTRODUCTION
1.1 DEFINATION:
The study of carburizing and nitriding heat treatment process
effect on losses in helical gear pair. The main problem we are
facing in our project is oil churning losses in helical gear pair and
it’s effect on power transmission capacity of helical gear pair and
so we in this project is first going to do is we design helical gear
according to availability in market and do analysis in cad
software based on beam strength ,helix angle and material of gear
and it’s effect and after that we will choose gear according to our
requirement .after these we are going to do case hardening of
helical gear by two heat treatment process which are carburizing
and nitriding .after this we will make a test rig and take reading at
different torque ,speed and for different types of oil .from reading
we are going to plot chart and we will see the effect of churning
losses on both type of helical gear that is carburized gear and
nitride gear. Based on that we will see the which of the two should
be used to reduce losses in helical gear pair.
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1.2 OBJECTIVES:
To design a helical gear and its analysis and used of

helical gear in transmission system. Transmission system are
although highly efficient but there are some small losses due to
churn of lubricant. To study about carburizing and nitriding heat
treatment process on load independent power losses in helical
gear and also about churning losses , Windage losses, pocketing
losses and surface roughness and to study about effect of heat
treatment processes on power losses and efficiency of
transmission system..
1.3 PROBLEM STATEMENT:
Losses in helical gear pair is main concerned because it

reduces the power transmission capacity of helical gear also
reduce efficiency of helical gear in terms of life and torque
capacity. Following are main losses which we are concerned is as
follows:
1) Churning Losses.
2) Windage Losses.
3) Pocketing Losses.
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4) Losses Due To Surface Roughness.
1) Churning Losses:
Churning losses are basically because of churning of

lubricating oil on gear surface. Oil churning losses happen in gear
box and different pieces of vehicle power train where gear
revolves and there is an oil circulation around there.
2) Windage Losses:
Windage losses are because of air trapped between mating

teeth surface at high rotation of gear .air drag forces acting in
direction opposite to rotation motion of gear hence reduce the
power transmission capacity of helical gear.
3) Pocketing Losses:
Pocketing losses are because of oil impurity and dirt etc

trapped in between gap between mating gear surfaces and remain
there for some time till gear teeth don’t come out mash .hence it’s
causes losses in gear pair and reduces power transmitting capacity
and also efficiency of helical gear pair.
4) Losses Due To Surface Roughness:

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Surface roughness are phenomenon that completely remove
or make scratch on surface. There different type of surfaces
roughness are such as:
a) Pitting Failure
b) Scoring Failure
c) Corrosive Failure
d) Abrasive Failure
a) Pitting Failure:
It is surface fatigue failure caused by repetition of hertz

contact stress on gear surface. When contact stress exceed the
endurance limit of material this failure occur. Initially a small pit
is formed which start growing and caused the rupture of surface.
b) Scoring Failure:
Scoring failure is because of lubricating failure. Inadequate

lubrication oil, high tooth load and bad surface finish result in
breakage of oil film.
c) Corrosive Failure:
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It is because of chemical reaction of inadequate lubrication
oil. Dirt in lubricating oil or due to surrounding atmosphere which
is corrosive in nature this failure occur.
1.4 HEAT TREATMENT PROCESS‫׃‬
Heat treatment is process which is being carried out to

change the internal properties of metal to make the metal more
desirable for work. The first metal is subject to heat in blast
furnace and proper amount of time the metal is taken out and then
cooled the metal to change microstructure of metal to desirable
mechanical and physical properties.
Heat treatment of metal is carried out to improve it’s its

strength, durability, toughness, ductility, corrosion resistance and
resilience property.
In our project we are going to used two heat treatment

process to improve surface property of helical gear and two heat
treatment process which we are going to used is carburizing heat
treatment process and nitriding heat treatment process and we will
see the effect these two process on helical gear surface and
compare them to see which will better for helical gear.
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1.4.1 Carburizing Heat Treatment Process‫׃‬
Carburization is a heat treatment method within which iron

or steel absorbs carbon whereas the metal is heated within
the presence of a carbon-bearing material, like charcoal
or monoxide. The intent is to form the metal more
durable. Looking on the quantity of your time and temperature,
the affected space will vary in carbon content. Longer
carburizing times and better temperatures usually increase the
depth of carbon diffusion. Once the iron or steel is
cooled quickly by ending, carbon content on the outer surface
becomes exhausting because of the conversion from austenite
to marten site, whereas the core remains soft and hard as a ferrite
and/or lamellar mixture microstructure.
Following are specification which is to use in process are

Charcoal and barium carbonate powder should be 10:1 in ratio.
Charcoal provide carbon and barium carbonate will act as
activator during the process for carburizing heat treatment
temperature should above 950℃ for more than 2 hours.
Carburizing is heat treatment process result in gear feature a

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dipper hardened layer whose hardness continuously decrease to

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core hardness. Structure provide higher surface contact fatigue
property, ductility, impact resistance and core strength.
Appropriate amount of case depth is obtained in carburizing
process. Carburizing process involves some change in dimension
of gear which up to 0.3 inch. Carburized gear will handle 30 to 50
percent more load than the normal gear. Carburizing case depth
vary from 0.13 to 8.5 mm. For heavy loaded gear carburizing is
better choice compared to other heat treatment process and also
carburizing require less time.
1.4.2 Nitriding Heat Treatment Process:
Nitriding is a heat treatment method in which nitrogen layer

is diffuses on to the surface of metal to make case hardening
surface. Nitriding method is mostly used for low carbon, low
alloy steels. Nitriding is regularly done in the 495-565°c (925 to
1050°f) temperature go. Three factors that are very basic in
creating prevalent and steady nitride cases and unsurprising
dimensional change are steel organization, earlier structure, and
center hardness. Case profundity and case hardness properties
change not just with the length and sort of nitriding being
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performed, but on the other hand are impacted by these

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components. Ordinarily case profundities are between 0.20-0.65
mm (0.008"- 0.025") and take from 10 to 80 hours to deliver.
Nitriding gear can have a white layer on surfaces which is

very hard and brittle. If it is not removed it can prone to flaking
and lead to cracking and heavy surface fracture and gear failure.
Hardened case depth is thinner than carburized gear. For lightly
loaded precision parts where rupture can be major consideration,
nitriding case depth is of appropriate choice.
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CHAPTER 2.
LITERATURE REVIEW
2.1 J.POLLY, DAVID TALBOT, AHMET

KAHRAMAN, AVINASH SINGH, HAI XU:
In this study, load-independent (spin) power losses of a case

in operation below dip-lubrication condition are investigated
associate in nursing experiment employing a final drive spiraling
gear combine from an automotive transmission because the
example system.an avid case is developed to work one gear or
gear combine below given speed and temperature condition.
A check matrix that consists of sets of tests with (i) single

gears (spur, helical, or representative disks with no teeth), and
(ii) spiraling gear pairs is dead at varied temperatures, immersion
depths and pinion positions relative to its meshing gear. Power
losses from single gears and kit pairs at identical in
operation conditions are compared to quantify the parts of the
full spin loss within the variety of losses because of gear drag,
gear mesh pocketing, and bearings and seals.
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2.2 Yasutsune ARIURA, Taku UENO, Teruo
SUNAGA, Shigemi SUNAMOTO:
Due to the bigger power loss caused by higher operational

powers and speeds the operating temperatures of gears systems in
use today square measure higher inflicting the strength of tooth
surfaces to decrease. Usually, the ability loss consists of (1) the
tooth friction, (2) the lubricator churning loss and (3) the bearing
loss.
During this paper, the churning loss is mentioned. Primarily,

lubricants square measure used for decreasing tooth friction and
for dissipating the warmth generated, and so as to understand the
most effective technique of lubrication the number of churning
loss and its cause ought to be determined.
Within the gift experiment, the churning loss of a cogwheel

system with jet lubrication is measured, and several other
analyses square measure planned. From the results therefrom, it
becomes clear that the churning loss consists of the ability needed
to lure the oil between the coupling gears and to accelerate the
oil within the tooth area. And it's thought of that at high speeds
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the churning loss doesn’t become thus giant despite the
consistence of the oil.
2.3 Patrick Albers, C. Changenet, Dr. P.A. Veenhuizen
After finding out the previous results and creating the

required measure it becomes plain the oil churning losses, that is
con to the previous formula derived by MACIAN- VOUTAY,
this independence of consistence for top speed can end in the
removal of the sir JOSHUA REYNOLDS variety within the
formula that was derived by a with the results of the created
measure the coefficients for the new formula are derived. When
the 2 formulae for top speeds are compared with the measured
power losses at high speed, it seems the new formula has higher
results for the measure. Thanks to the coefficients within the new
formula don't seem to be dependent of the pure mathematics, not
for all issue 0.25 and low oil churning losses the new formula
provides worse results. To search out affiliation between the 2
formulae for low and high speed a brand new sir JOSHUA
REYNOLDS this variety determines that formula underneath
sure conditions are used. Once this sir JOSHUA REYNOLDS
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variety was applied to discretionary geometries it seems this
variety.
2.4 Joseph H. Polly:
An extensive experimental study was conducted to

investigate the components of spin power loss of an automotive
final drive helical gear pair. Developed for this purpose with the
ability to spin an unloaded gear pair or a single gear in various
operating conditions while measuring torque provided to the
gearbox. Set-up was shown to be capable of producing repeatable
power loss measurements within an input ring gear speed range
of [0, 2000] rpm and at bulk lubricant temperatures a test matrix
was defined and executed that allowed determination of the main
components of spin power loss of the gear box, namely
(i) Drag loss of the ring gear,

(ii) Drag loss of the gear shaft bearings/seals,
(iii) Drag loss of the pinion shaft bearings/seals,
(iv) Lubricants, gear sizes, tooth shapes (including disks
with no teeth), single gear and gear pair configurations.
Input shaft tests with no gears were employed to isolate

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bearing and seal losses while single ring gear tests were used to
quantify ring gear drag losses at comparing these sub-system tests
to gear pair spin loss tests resulted in the contributions of gear
mesh pocketing to overall spin loss. These tests, that quantified
the impact of rotational speed, bulk lubricant temperature, pinion
position angle and static lubricant level on spin losses, were
extended through design and implementation of various
enclosures and shrouds around the ring gear to study the influence
of the shape of the surroundings on the gear drag losses.
FIGURE [01]: EXPERIMENTAL SETUP
2.5 Satya Seetha Raman:
This dissertation lays the framework for a physics-based

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fluid mechanics model to predict oil churning and Windage

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power losses in gear pairs. Windage power loss models, both
developed for the case of a spur gear pair, have been validated
through comparisons to power loss measurements conducted on
a family of unity-ratio spur gear pairs, under dip- and jet-
lubricated conditions. Carried out over a wide range of operating
conditions, different oil immersion depths, lubrication conditions
and through variations in gear geometry parameters, to enhance
the influence of key system parameters were also quantified
through detailed example analyses of the respective power loss
models. Further, the oil churning power loss model, in
conjunction with a mechanical power loss model and existing
bearing power loss models, has been generalized, in the form of a
transmission power loss model, to predict the total power loss in
automotive power loss measurements on a sample six-speed
manual transmission corroborate the predictions of the proposed
transmission power loss model.
The power loss computation methodologies proposed in this

dissertation have the potential to be generalized so as to form the
foundation for future formulations that can handle other types of
complex gear drives, beyond just spur and helical. More highly
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stressed that in lieu of the lack of physics-based models that exist
in transmission power loss literature, the models developed in this
dissertation, with all their limitations, present a detailed first-stab
towards the prediction of power losses in gears without
compromising on computational efficiency in providing a clear
window into the mechanism.
2.6 A.Y Gidado, I. Muhammad, A. A. Umar:
Face width and helix angle are important geometrical

parameters in determining the state of stresses during the thus, the
objective of this work is to conduct a parametric study by varying
the face width to study their determine the stresses variation with
the face width five different models of helical were created by
keeping other module, pitch circle diameter, number of teeth,
helix angle etc) constant. The results obtained from ANSYS when
compare with the AGMA procedure, it shows that there is a little
variation with we can conclude that ANSYS can also be used for
predicting the values of bending stress at any required face width
which is much easier to use to solve complex design problems
like gears.
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2.7 K. NARESH, C. CHANDRUDHU:
Modeling and analysis of helical gear is done in solid works.

Helical gear is designed by using various commands in solid
works. 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
aluminum silicon carbide and grey cast iron are more preferable
when compared to chrome stainless steel because at a given load
it is showing breakage.
2.8 MALLA MAHESH , Dr. S RAMAKRISHNA:
Modelling and analysis is done in CREO parametric 3.0 and

ANSYS workbench respectively. Pressure angle, helix angle and
face widths are the important parameters in determining the state
of stress during the design of gears. By observing the analysis
results, the stress values obtained are less than their yield stress.
It can be concluded that the design is safe under working
conditions. The design at stage 1 and 2 are within in the safe under
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working conditions and it is seen at stage 3 that the stresses were

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more than the yield stress. So, the re design of helical gear at the
stage 3 with constant module, face width, constant pressure angle
20 and varying helix angles (14,15,16,17,20,25, and 30) is done
in CREO. The stresses for the remodeled gears were calculated
according to the AGMA theory and the numerical analysis is done
at different helix angles with constant face width. It is seen that
the contact stress at 14 degrees is comparably less at the same
module and working conditions of the SPTC gear box.
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CHAPTER 3.
DESIGN AND SPECIFICATION
3.1 GEAR TERMINOLOGY:

3.1.1 Figure Shows The Terminology Related To Gear:
FIGURE [02]: GEAR TERMINOLOGY (a)
Number of teeth
Transvers module =6
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FIGURE [03]: GEAR TERMINOLOGY (b)
3.2 DESIGN OF HELICAL GEAR FOR

DIFFERENT HELIX ANGLE:
3.2.1 Calculation Of Gear Terminology:
 Pitch circle diameter (PCD)
 Normal module (mn)

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 Transverse circular pitch (Ptc)
 Normal circular pitch (Pnc)
 Transverse diametral pitch (Ptd)
 Normal diametral pitch (Pnd)

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 Axial pitch (Pa)
 Addendum (Ha)
 Dedendum (Hf)
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 Addendum circle diameter (DHa)
155.27
 Dedendum circle diameter (DHf)
 Base circle diameter (Db)
 Tooth face width (b)

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 Normal pressure angle (Øn)
Table Number [01]:Terminology of Gear With Helix Angle 20

Sr. no. Gear terminology Unit Symbol Gear-1
1 Helix angle Degree α 20
2 Transverse module mm mt 6
3 Normal module mm mn 5.638
4 Pitch circle diameter mm PCD 144
5 Number of teeth - Z 24
6 Pressure angle Degree Ø 20
7 Normal pressure angle Degree Øn 18.88
8 Transverse circular pitch mm Ptc 18.85
9 Normal circular pitch mm Pnc 17.71
-1
10 Transverse diametral pitch mm Ptd 0.167
11 Normal diametral pitch mm-1 Pnd 0.178
12 Addendum mm Ha 5.64
13 Dedendum mm Hf 7.05
14 Addendum circle diameter mm DHa 155.27
15 Dedendum circle diameter mm DHf 129.91
16 Base circle diameter mm Db 135.32
17 Axial pitch mm Pa 51.78
18 Tooth face width mm b 59.54
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FIGURE [04]: SOLID WORKS MODEL
 Same as other gear terminology with helix angle varies from

20 to 30.
Table Number [02]: Terminology of Gear

Sr. Symbol Unit Gear-2 Gear-3 Gear-4 Gear-5 Gear-6
no.
1 α Degree 22 24 26 28 30
2 mt mm 6 6 6 6 6
3 mn mm 5.563 5.4812 5.392 5.297 5.196
4 PCD mm 144 144 144 144 144
5 Z - 24 24 24 24 24
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6 Ø Degree 20 20 20 20 20
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7 Øn Degree 18.65 18.39 18.11 17.82 17.495
8 Ptc mm 18.85 18.85 18.85 18.85 18.85
9 Pnc mm 17.47 17.22 16.94 16.64 16.32
10 Ptd mm-1 0.167 0.167 0.167 0.167 0.167
11 Pnd mm-1 0.18 0.182 0.185 0.189 0.193
12 Ha mm 5.563 5.4812 5.392 5.297 5.196
13 Hf mm 6.953 6.8515 6.74 6.6212 6.495
14 DHa mm 155.126 154.962 154.78 154.59 154.39
15 DHf mm 130.096 130.297 130.52 130.78 131.01
16 Db mm 135.315 135.315 135.315 135.315 135.315
17 Pa mm 46.655 42.33 38.65 35.45 32.65
18 b mm 53.65 48.68 44.45 40.77 37.55
3.2.2 Calculation Of Load And Stress:

 Gear rotates at 1500 rpm and power transmit 35 KW and
force applied is 3100 N and static stress
 rpm

 N
 Equivalent number of teeth (TE)
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 Pitch line velocity (V)
 Velocity factor (CV)
 Lewi’s form factor (Y)
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 Transmitted torque (MT)
 Tangential load (WT)
 End trust on the gear (WT)
 Beam stress (Sb)

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Table Number [03]: Load and Stress
Sr. Data Unit Symbol Value
No.
1 Equivalent number of - TE 28.923
teeth
2 Pitch line velocity m/s V 11.31
3 Velocity factor - CV 0.625
4 Lewi’s form factor - Y 0.122
5 Transmitted torque N MT 222.82
6 Tangential load N WT 3094.67
7 End trust on the gear N WA 1126.36
8 Beam strength N/mm2 Sb 1433.89
 Same as other gear load and stress values are following in

table number [4] with helix angle varies from 20 to 30.
Table Number [04]

Sr. Symbol Unit Gear-2 Gear- Gear-4 Gear-5 Gear-6
no. 3
1 TE - 30.11 31.478 33.054 34.866 36.95
2 V m/s 11.31 11.31 11.31 11.31 11.31
3 CV - 0.625 0.625 0.625 0.625 0.625
4 Y - 0.1237 0.125 0.126 0.1278 0.1293
5 MT N 222.82 222.82 222.82 222.82 222.82
6 WT N 3094.67 3094.67 3094.67 3094.67 3094.67
7 WA N 1250.327 1377.83 1509.37 1645.46 1786.71
39
8 Sb N/mm2 1307.72 1167.36 1056.94 965.98 882.97

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CHAPTER 4.
BEAM STRENGTH ANALYSIS OF
HELICAL GEAR
4.1 ANALYSIS OF HELICAL GEAR FOR
DIFFERENT HELIX ANGLE.
 Using Cast Steel for Gear Model Analysis in ANYSIS.
 Cast Steel Properties Is In Following Table [05]:
Table Number [05] : Properties Cast Steel

Material Properties
Sr. no. Data Unit Value
3
1 Density Kg/m 7820
2 Young's modulus pa Pa 121544.51
3 Poisson's ratio - 0.3
4 Bulk modulus Pa 101289.08
5 Shear modulus Pa 171976.04
6 Thermal conductivity W/m c 60.4
-1
7 Coefficient of thermal expansion C 7.75 x 10-3
8 Specific heat J/kg c 496
9 Tensile yield strength Pa 10403.54
10 Tensile ultimate strength Pa 15058.83
 Apply 3100 N force apply on the gear tooth face.

 Gear tooth are fixed at its base.
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4.1.1 Analysis for gear with helix angle is 20 degree.
FIGURE [05]: Von Mises Stress for Helix Angle 20
Table Number [06]:Data Related of Analysis

Sr. No. Data Unit Value
3
1 Volume m 0.166
2 Mass Kg 7.093
3 Environmental temperature C 22
4 Analysis type - Static structural
5 Nodes - 16106
6 Elements - 9274
7 Equivalent Maximum Pa 1738.38
8 stress Minimum Pa 772.32
9 Maximum shear stress Pa 454.51
41
10 Deformation mm 11.06
Page
Table Number [07] : Data Related of Analysis

3
1 Volume m 0.149
2 Mass Kg 6.392
4 Analysis type - Static Structural
5 Nodes - 19099
6 Elements - 10736
42

Page

3
1 Volume m 0.1359
2 Mass Kg 5.804
4 Analysis type - Static structural
5 Nodes - 15750
6 Elements - 8982
43
Page

3
1 Volume m 0.1240
2 Mass Kg 5.2973
5 Nodes - 15930
6 Elements - 9001
44
Page

3
1 Volume m 0.1166
2 Mass Kg 4.9788
5 Nodes - 18004
6 Elements - 10197
45
Page

1 Volume m3 0.1048
2 Mass Kg 4.4771
5 Nodes - 19083
6 Elements - 10629
46
Page
4.2 ANALYSIS OF HELICAL GEAR FOR
DIFFERENT MATERIAL:
4.2.1 Analysis for gear with material is gray cast iron:
 Gear terminology as same as Table Number [1].

 Material properties is given in following Table.
Table Number [12]: Properties of Grey Cast Iron

Material: Grey Cast Iron
3
1 Density Kg/m 7200
6 Thermal conductivity W/m c 52
-1
7 Coefficient of thermal expansion C 7.411x10-3
9 Tensile yield strength Pa 0
47
Page
FIGURE [11]: Von Mises Stress for Grey Cast Iron
Table Number [13]:

1 Volume m3 0.1661
2 Mass Kg 6.5306
5 Nodes - 16106
6 Elements - 9274
48
Page
4.2.2 Analysis for gear which material is Structural Steel:
Table Number [14]: Properties of Structural Steel

Material: Structural Steel
3
1 Density Kg/m 7850
7 Coefficient of thermal expansion C-1 8.085x10-3
49
Page
FIGURE [12]: Von Mises Stress for Structural Steel
Table Number [15]

1 Volume m3 0.166
2 Mass Kg 7.1202
5 Nodes - 16106
6 Elements - 9274
50
Page
4.2.3 Analysis for gear which material is Cast Steel:
Table Number [16]: Properties of Cast Steel

Material: Cast Steel
3
1 Density Kg/m 7820
-1
7 Coefficient of thermal expansion C 7.75 x 10-3
51
Page
FIGURE [13]: Von Mises Stress for Cast Steel
Table Number [17]:

1 Volume m3 0.166
2 Mass Kg 7.093
5 Nodes - 16106
6 Elements - 9274
52
Page
4.2.4 Analysis for gear which material is Cast Steel:
Table Number [18]: Properties of Magnesium Alloy

Material: Magnesium Alloy
3
1 Density Kg/m 7820
2 Young's modulus pa Pa 1800
-1
7 Coefficient of thermal expansion C 156
8 Specific heat J/kg c 17.51x10-3
9 Tensile yield strength Pa 1024
53
Page
FIGURE [14]: Von Mises Stress for Magnesium Alloy
Table Number [19]:

1 Volume m3 0.166
2 Mass Kg 1.6327
5 Nodes - 16106
6 Elements - 9274
54
Page
CHAPTER 5.
CONCLUSION
Based On Fea Analysis Of Helical Gear We Conclude That
As Helix Angle Increases The Bending Endurance Strength Of
Helical Gear Also Increases And As Value Of Helix Angle
Decrease The Bending Endurance Strength Of Helical Gear Also
Decrease For Same Gear Material .The Best Range For Helix
Angle Based On Fea Analysis Of Helical Gear Is Between 22-26
Degree For Experiment Purposes As Well For Application
Purposes Of Helical Gear.
Fea Analysis Of Helical Gear For Different Gear Material

Such As Cast Steel, Structural Steel, Magnesium Alloy ,
Aluminum Alloy , Stainless Steel And Grey Cast Iron For Same
Gear Parameter We Conclude That Bending Endurance Strength
Of Helical Gear Is Maximum For Grey Cast Iron And Minimum
For Magnesium Alloy. 55
Page
CHAPTER 6.
PLANNING FOR NEXT PHASE
1. Selection of Helical Gear for Experiment Based On Fea

Analysis.
2. Experimental Set up Development for Measurement of Helical
Gear Losses.
3. Helical Gear Losses Measurement.
4. Based Losses Measurement We Will Plot Chart In Matlab.
5. Optimization of Helical Gear.
56
Page
CHAPTER 7.
REFERNCES
1. J. Polly , David Talbot , Ahmet Kahraman , Avinash Singh ,
Hai Xu., An Experimental Investigation of Churning Power
Losses of a Gearbox V010T11A043; 11 pages November 3,
2017.
2. Yasutsune ARIURA, Taku UENO, Teruo SUNAGA, Shigemi
SUNAMOTO.,The Lubricant Churning Loss in Spur Gear
Systems, INTERNATIONAL JOURNAL February 15, 2008.
3. Patrick Albers,C. Changenet,Dr. P.A. Veenhuizen.,A study to
oil churning losses in a gearbox, Report number: DCT-200413
5, FEBRUARY 2004.
4. Joseph H. Polly, AN EXPERIMENTAL INVESTIGATION
OF CHURNING POWER LOSSES OF A GEARBOX, master
thesis, the Ohio State University, 2013.
5. Satya Seetharaman,AN INVESTIGATION OF LOAD-
INDEPENDENT POWER LOSSES OF GEAR
SYSTEMS,phd thesis,The Ohio State University,2009.
6. A.Y Gidado, I. Muhammad, A. A. Umar,Design, Modeling and
Analysis of Helical Gear According Bending StrengthUsing
AGMA and ANSYS,International Journal of Engineering
Trends and Technology (IJETT) – Volume 8 Issue 3- Febuary
2014.
7. K. NARESH, C. CHANDRUDHU, DESIGN AND
ANALYSIS OF HELICAL GEAR, INTERNATIONAL
JOURNAL OF PROFESSIONAL ENGINEERING
STUDIES, Volume VI /Issue 4 / AUG 2016.
8. Malla Mahesh , Dr. S Ramakrishna, Design And Analysis Of
57
Helical Gear In Slag Port Transfer Car Gear Box ,International

Page
Journal Of Advance Engineering And Research Development
Volume 5, Issue 04, April -2018.
9. Machine Design Book by V.B.Bhandari.
10. Machine Design Book by R.S.Khurmi and J.K.Gupta.
58
Page
APPENDIX-A
DESIGN ENGINEERING CANVAS
1. AEIOU CANVAS:
59
Page
2. EMPATY MAPPING CANVAS:
60
Page
3. IDEATION CANVAS:
61
Page
4. PRODUCT DEVLOPMENT CANVAS:
62
Page

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GUJARAT TECHNOLOGICAL UNIVERSITY

Chandkheda, Ahmedabad Affiliated

Government Engineering College

TO STUDY THE EFFECT OF CARURIZING AND NITRIDING

Group ID: - 58148

Prof. U.R.BHUVA (AUTOMOBILE)

Prof. K.D.CHAUDHARI (AUTOMOBILE)

Academic year (2019-20)

Internal Guide: Head of the Department

Prof. U.R.Bhuva Asst. Prof. K.D.Chaudhari

Automobile Department Automobile Department

G.E.C. Rajkot G.E.C. Rajkot

Internal Guide: Head of the Department

Prof. U.R.Bhuva Asst. Prof. K.D.Chaudhari

Automobile Department Automobile Department

G.E.C. Rajkot G.E.C. Rajkot

Internal Guide: Head of the Department

Prof. U.R.Bhuva Asst. Prof. K.D.Chaudhari

Automobile Department Automobile Department

G.E.C. Rajkot G.E.C. Rajkot

Internal Guide: Head of the Department

Prof. U.R.Bhuva Asst. Prof. K.D.Chaudhari

Automobile Department Automobile Department

G.E.C. Rajkot G.E.C. Rajkot

We have taken many efforts in this project. However, it

We are highly indebted to “Prof. U.R.BHUVA” for their

We even thank and appreciate to our colleague in developing

To Design A Helical Gear And Its Analysis And Used Of

To design a helical gear and its analysis and used of

1.3 PROBLEM STATEMENT:

Losses in helical gear pair is main concerned because it

Churning losses are basically because of churning of

Windage losses are because of air trapped between mating

Pocketing losses are because of oil impurity and dirt etc

4) Losses Due To Surface Roughness:

It is surface fatigue failure caused by repetition of hertz

Scoring failure is because of lubricating failure. Inadequate

1.4 HEAT TREATMENT PROCESS‫׃‬

Heat treatment is process which is being carried out to

Heat treatment of metal is carried out to improve it’s its

In our project we are going to used two heat treatment

Carburization is a heat treatment method within which iron

Following are specification which is to use in process are

Carburizing is heat treatment process result in gear feature a

dipper hardened layer whose hardness continuously decrease to

1.4.2 Nitriding Heat Treatment Process:

Nitriding is a heat treatment method in which nitrogen layer

performed, but on the other hand are impacted by these

Nitriding gear can have a white layer on surfaces which is

2.1 J.POLLY, DAVID TALBOT, AHMET

In this study, load-independent (spin) power losses of a case

A check matrix that consists of sets of tests with (i) single

Due to the bigger power loss caused by higher operational

During this paper, the churning loss is mentioned. Primarily,

Within the gift experiment, the churning loss of a cogwheel

2.3 Patrick Albers, C. Changenet, Dr. P.A. Veenhuizen

After finding out the previous results and creating the

2.4 Joseph H. Polly:

An extensive experimental study was conducted to

(i) Drag loss of the ring gear,

Input shaft tests with no gears were employed to isolate

FIGURE [01]: EXPERIMENTAL SETUP