Rajesh Final Book@28!11!16

1 INTRODUCTION
1.1 DEFINITION OF GEARS
Gears are toothed members which transmit power or motion between two
shafts by meshing without any slip. Hence, gear drives are also called as positive
drives. In pair of gears, the smaller one is called pinion and the larger one is called
gear immaterial of which is driving the other. When pinion is the driver, it results in
step down drive in which the output speed decreases and the torque increases. On the
other hand, when the gear is the driver, it results in step up drive in which the output
speed increases and the torque decreases.
1.2 CLASSIFICATION OF GEARS

Classification of gears can be done according to relative position of the axes of
revolution into three types. They are
 Gears for Parallel shafts
 Spur Gears
 Helical Gears
 Herringbone Gears
 Gears for Intersecting Shafts
 Straight Bevel Gears
 Spiral Bevel Gears
 Gears for Skew Shafts
 Hypoid Gears
 Worm Gears
1.2.1 Gears for Parallel shafts
The motion between parallel shafts is same as to the rolling of two cylinders.
Gears under this category are the following:
1.2.1.1 Spur Gears

Straight Spur gears are the simplest form of gears having teeth parallel to the
gear axis. The contact of two teeth takes place over the entire width along a line
parallel to the axes of rotation. As gear rotate, the line of contact goes on shifting
parallel to the shaft.
1
Figure 1.2 Helical Gears
Figure 1.1 Spur gears
1.2.1.2 Helical Gears
In helical gear teeth are part of helix instead of straight across the gear parallel
to the axis. The mating gears will have same helix angle but in opposite direction for
proper mating. As the gear rotates, the contact shifts along the line of contact across
the teeth.
Figure 1.3 Herringbone Gears Figure 1.4 Rack and Pinion

1.2.1.3 Herringbone Gears
Herringbone gears are also known as Double Helical Gears. Herringbone

gears are made of two helical gears with opposite helix angles, which can be up to 45
degrees.
2
1.2.1.4 Rack and Pinion
In these gears the spur rack can be considered to be spur gear of infinite pitch
radius with its axis of rotation placed at infinity parallel to that of pinion. The pinion
rotates while the rack translates.
1.2.2 Gears for intersecting shafts
The motion between two intersecting shafts is equivalent to the rolling of two
cones. The gears used for intersecting shafts are called bevel gears. Gears under this
category are following:
1.2.2.1 Straight Bevel Gears
Straight bevel gears are provided with straight teeth, radial to the point of
intersection of the shaft axes and vary in cross section through the length inside
generator of the cone. Straight Bevel Gears can be seen as modified version of
straight spur gears in which teeth are made in conical direction instead of parallel to
axis.
Figure 1.5 Straight Bevel Gears Figure 1.6 Spiral Bevel Gears
1.2.2.2 Spiral Bevel Gears
Bevel gears are made with their teeth are inclined at an angle to face of the
bevel. Spiral gears are also known as helical bevels.
3
1.2.3 Gears for Skew Shafts
The following gears are used to join two non-parallel and non-intersecting
shafts.
1.2.3.1 Hypoid Gears
The Hypoid Gears are made of the frusta of hyperboloids of revolution. Two
matching hypoid gears are made by revolving the same line of contact, these gears are
not interchangeable.
1.2.3.2 Worm Gears
The Worm Gears are used to connect skewed shafts, but not necessarily at
right angles. Teeth on worm gear are cut continuously like the threads on a screw. The
gear meshing with the worm gear is known as worm wheel and combination is known
as worm and worm wheel.
Figure 1.7 Hypoid Gears Figure 1.8 Worm Gears

1.3 BASIC GEAR TERMINOLOGY
The following are the important dimensions and geometries concerned with
toothed gear
4
1.3.1 Pitch Circle
Pitch circle is the apparent circle that two gears can be taken like smooth
cylinders rolling without friction.
1.3.1.1 Addendum Circle

Addendum circle is the outer most profile circle of a gear. Addendum is the
radial distance between the pitch circle and the addendum circle.
1.3.1.2 Dedendum Circle

Dedendum circle is the inner most profile circle. Dedendum is the radial
distance between the pitch circle and the dedendum circle.
1.3.1.3 Clearance
Clearance is the radial distance from top of the tooth to the bottom of the tooth
space in the mating gear.
Figure 1.9 Basic Gear Terminology

1.3.1.4 Backlash
It is the difference between the tooth space and the tooth thickness, as
measured on the pitch circle.
1.3.1.5 Full Depth

Full depth is sum of the addendum and the dedendum.
5
1.3.1.6 Face Width
Face width is length of tooth parallel to axes.
1.3.1.7 Diametral Pitch

It is the ratio of number of teeth to the pitch circle diameter in millimetres. It
denoted by pd.
1.3.1.8 Module
It is the ratio of the pitch circle diameter in millimetres to the number of teeth.
It is usually denoted by m.
m = d/Z
Where d= pitch circle diameter
Z= Number of teeth
1.3.1.9 Circular Pitch

It is the distance measured on the circumference of the pitch circle from a
point of one tooth to the corresponding point on the next tooth. It is usually denoted
by pc.
1.3.1.10 Gear Ratio

Gear ratio is numbers of teeth of larger gear to smaller gear.
1.3.1.11 Pressure Line

Pressure line is the common normal at the point of contact of mating gears
along which the driving tooth exerts force on the driven tooth.
1.3.1.12 Pressure Angle

Pressure angle is the angle between the common normal drawn at point of
contact and common tangent of pitch circles at pitch point. It is also called angle of
obliquity. High pressure angle requires wider base and stronger teeth.
1.3.1.13 Pitch Angle

It is the angle made by the pitch line with the axis of the shaft. It is denoted by θP.
6
1.4 LAW OF GEARING
Law of gearing states that common normal to the tooth profile at the point of
contact should always pass through a fixed point called pitch point in order to obtain a
constant velocity ratio.
Figure 1.10 Law of Gearing

Where gear wheel-1 is considered point Q moves in the direction of QC.
Velocity along QC is V1. Where gear wheel-2 is considered point Q moves in the
direction of QD. Velocity along QD is V2. As the teeth are to remain in contact, then
the components of these velocities along the common normal MN must be equal.
1.4.1 Derivation of law of gearing
V =v 1 cosα=v 2 cosβ … … 1
V 1=O1 Q w1 … … … … 2
V 2=O 2 Q w2 … … 3
Substituting 2 and 3 in 1 we get,
V =O1 Q w1 cosα=O2 Q w2 cosβ … … .4
O1 M O2 N
cosα= … …5 ; cosβ= … … … .. 6
O1 Q O2 Q
7
Substituting 5 and 6 in 4 we get,
O1 M O2 N
O1 Q w 1 × =O 2 Q w2 ×
O1 Q O2 Q
w1 O2 N
= … … … .7
w2 O1 M
Consider similar triangles O1MP and O2NP as shown below,
O2 N d 2 Z 2
= = … … … ….8
O1 M d1 Z 1
Substituting 8 in 7 we get,
w1 Z 2
=
w2 Z 1
Hence it is proved that velocity ratio is constant.
1.5 BEAM STRENGTH OF BEVEL GEARS
The size of cross section of the tooth of a bevel gear varies along the face
width. In order to determine the beam strength of the tooth of a bevel gear, it is
considered to be equivalent to a formative spur gear in a plane perpendicular to the
tooth element.
Consider an elemental section of the tooth at a distance x from the apex o and
having a widthdx . Applying the Lewis equation to a formative spur gear at a distance
x from the apex,
δ ( S b )=mx × b x × σ b × Y ……………..(a)
Where, δ ( S b )=¿ Beam strength of the elemental section (N)

mx =¿ Module of the section
b x =¿ Face width of elemental section (mm)
Y = Lewis form factor based on virtual number of teeth
From the figure,
rx x Rx
= ∨r x = … … … … … … … … … … …(b)
R Ao Ao
8
The elemental section,
2 r x 2 xR
mx = = ………………..(c)
Z Z Ao
At the large end of the tooth,
2R
mx = ……………………… (d)
Z
From (c) and (d),

x
mx =m( )……………………… (e)
Ao
b x =dx ………………………….. (f)
Substituting (e) and (f) in (a) we get

x
δ ( S b )=m( )× dx × σ b ×Y …….. (g)
Ao
Now we get,
[ ]
2
b b
M t =m× b ×σ b × Y × R 1− + …… (h)
A o 3 Ao 2
Assuming beam strength ( Sb ¿ as the tangential force at the large end of tooth,
M T =S b × R…………… (i)
From (h) and (i)
[ ]
2
b b
Sb =m× b ×σ b × y 1− +
Ao 3 AO 2
The face width of the bevel gear is limited to one-third of the cone distance.
Therefore, the last term in the bracket will never be more than (1/27).
Neglecting the last term,
Sb =m× b ×σ b × y 1−
[ b
Ao ]
Where,
( Sb ) =¿ Beam strength of the tooth (N)
m¿ Module at the large end of the tooth (mm)
b ¿ Face width (mm)
Y = Lewis form factor based on virtual number of teeth
9
Ao =¿ Cone distance (mm)
[ 1−
b
Ao]= is called bevel factor.
1.6 WEAR STRENGTH OF BEVEL GEARS
The contact between two meshing teeth of straight bevel gears is a line
contact, which is similar to that of spur gears. In order to determine the wear strength,
the bevel gear is considered to be equivalent to a formative spur gear in a plane which
is perpendicular to the tooth at the large end. Applying Buckingham’s equation to
those formative gears,
Sw =b ×Q ×d p' × K …………….. (a)
Where,
b = face width of gears (mm)
Q = ratio factor
'
d p =¿ Pitch circle diameter of the formative pinion (mm)
K = material constant (N/mm2 )
The pitch circle diameter of the formative pinion is given by
'
d p =2 r b
Substituting equation in the above expression,
' Dp
dp = ……………….. (b)
COSγ
Where D p is the pitch circle diameter of the pinion at the large end of the tooth. From
(a) and (b),
b × Q× D p × K
SW = … … … … ..(C )
COSγ
In case of bevel gears, either the pinion or the bevel gear is generally
overhanging. It is subjected to deflection under the action of tooth forces and it has
been found that to transmit the load, only three quarters of the face width is effective.
Modifying Eq.(c) to account for this effect,
0.75 × b ×Q × D p × K
SW = … … … ….. ( d )
COSγ
10
Equation (d) is known as Buckingham’s equation for the wear strength of
bevel gears. The equation is derived for the formative pair of pinion and gear, the
ratio factor Q is, therefore, given by
'
2 Zg
Q= ' ' ……………… (e)
zg + Z p
But we have,
Zp
Z'p =
COSγ
And
' Zg Zg Zg
Z g= = =
COSγ cos (90−γ ) SINγ
Substituting above equations in (e)
2 Zg
Q=
Z g +Z p tanγ
The material constant K is the same as for the spur gears and is given by
K=
σ 2c × sinα ×cosα
[ 1 1
+
Ep Eg ]
1.4
When the pinion as well as gear is made of steel and pressure is 20 degree the value of
K is given by
( )
2
BHN
K=0.16
100
The wear strength indicates the maximum value of the tangential force at the large
end of the tooth that the tooth can transmit without pitting failure. It should be more
than the effective force between the meshing teeth.
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2 LITERATURE REVIEW
2.1 BENDING STRESSES OF BEVEL GEARS
Ratnadeepnish M.Jadeja et al [1] Here in this paper after doing the

analytical calculation and analysis in ANSYS of straight teeth bevel gear, spiral bevel
gear and zerol bevel gear, one conclude that the features of zerol bevel gear are good
for the power transmission at higher speed and higher load. The zerol bevel gear has
higher strength to resist the stress. Because of the curvature shape of the teeth load
distribution is in two directional and continuously distribute the load in two
directions, while in straight bevel gear load is applied in line form and at same time in
full teeth. They have meshed the part by taking tetrahedron element and element size
is 1mm and faces are 0.5mm for those areas where the stress concentration is high.
Two of the surfaces are fixed in the reference of the gear teeth where the load is
applied. Here load is applied in the form of pressure. The amount of tangential load is
applied on the some specific area of the gear teeth by the pinion. That area is defining
as the contact region of the gear teeth and the pinion teeth.
This paper can recommend the zerol bevel gear for transmission of power at
90° instead the spiral bevel gear and straight teeth bevel gear because of the following
reason:
 Easy to manufacture compare to straight teeth bevel gear and spiral bevel gear
 Have a high strength to resist the stress.
 Work without any noise at high speed because of its curvature surface pitting
effect reduces.
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2.2 BENDING STRENGTH OF BEVEL GEAR BY FEM
Abhijeet v. patil et al [2] prepared solid modeling in CATIA and meshing
is done. Analysis is done by using ANSYS workbench 12.1.In this project they
have taken static structural material and given design inputs such as power 2.2kw,
Number of teeth of pinion 20, Pitch diameter of pinion 60mm, Module 03mm and
pressure angle 20deg.They calculated theoretical and got the bending strength value
as 36.38N/mm2.By analysis the bending strength value is 36.17N/mm2 There is
fairly good agreement between experimental and finite element results. The error in
maximum bending stress is found to be 10%. They found that In bevel gear the
bending stresses produced at critical section (root of tooth) are maximum as
compared to spur gear.
2.3 COMPUTERIZED DESIGN OF ADVANCED STRAIGHT AND SKEW

BEVEL GEARS BY PRECISION FORGING
Alfosnso Fuentes et al [3] In this project they prepared computerized design
of advanced straight and skew bevel gears produced by precision forging is
proposed .Modifications of the tooth surfaces of one of the members of the gear set
are proposed in order to localize the bearing contact and pre design a favorable
function of transmission errors. The proposed modifications of the tooth surfaces will
be computed by using a modified imaginary crown-gear and applied in
manufacturing through the use of the proper die geometry. The geometry of the die is
obtained for each member of the gear set from their theoretical geometry obtained
considering its generation by the corresponding imaginary crown-gear. Two types of
surface modification, whole and partial crowning, are investigated in order to get the
more effective way of surface modification of skew and straight bevel gears. A
favorable function of transmission errors is predesigned to allow low levels of noise
and vibration of the gear drive. Numerical examples of design of both skew and
straight bevel gear drives are included to illustrate the advantages of the proposed
geometry.
2.4 BEVEL GEAR TOOTH BENDING STRESS EVALUATION USING

FINITE ELEMENT ANALYSIS
Emre turkoz et al [4] studied the problem that the static application of a
moment of 600000 Nmm on the pinion, which tries to rotate but is hindered by the
grounded gear. The torque is transferred to the gear through contact faces on tooth
13
pairs. The moment causes on these pairs a contact force to be generated. Apart from
the contact stress this force forms, roots of the contact teeth also suffer from tooth
root bending stress. In this paper the aim of the work is the evaluation of this root
bending stress generated during the static application of the moment. The numerical
and the analytical solutions are compared to validate the model used for the finite
element analysis.
The finite element analysis results are pretty much close to the analytically
evaluated results. The mean tooth root bending stress, evaluated by selecting the
nodes at the root of the contact teeth, has the value of 37,016 MPa, which corresponds
to the 17% difference with the analytical result.
We see a great similarity between the numerical and the analytical results.
From the results evaluated, it can be said that the FEA Analysis is validated. The
difference in between is caused by many factors. The accuracy of the FEA results
may be increased by using more mesh elements, which encapsulate contact regions
more densely. Also a smaller tolerance for the solution of the stiffness matrix can be
imposed.
2.5 DESIGN OF CONTACT STRESS ANALYSIS OF STRAIGHT BEVEL

GEARS
F. K. Choyetal et al [5], provided a comparison and benchmarking of
experimental results obtained from a damaged gear transmission system with those
generated from numerical model. conclusions for this study as follows: 1. A study of
the dynamic changes in a gear transmission system due to (a) no gear tooth damage,
(b) single gear tooth damage,(c) two consecutive gear teeth damage, and (d) three
consecutive gear teeth damage is successfully conducted. 2. The vibration signature
analysis using a joint time-frequency procedure, the Wigner-Ville distribution
(WVD), seems to be quite effective in identifying single and multiple teeth damage in
a gear transmission.
2.6 STRUCTURAL AND MODEL ANALYSIS OF A COMPOSITE

MATERIAL
B. Venkatesh et al. et al [6], obtained Von-Misses stress by theoretical and

ANSYS software for Aluminum alloy, values obtained from ANSYS are less than
that of the theoretical calculations. The natural frequencies and mode shapes are
14
important parameters in the design of a structure for dynamic loading conditions,
which are safe and less than the other materials like steel. Aluminum alloy reduces the
weight up to 5567% compared to the other materials. Aluminum is having unique
property (i.e. corrosive resistance), good surface finishing, hence it permits excellent
silent operation. Weight reduction is a very important criterion, in order to minimize
the unbalanced forces setup in the marine gear system, there by improves the system
performance. By the above exhaustive literature review, we can say that the gear
needs to be redesigned providing energy saving by weight reduction, providing
internal damping, reducing Lubrication requirement without increasing cost. Such a
scope is provided by application of composite material providing solution to other
existing problems in current gears available. Therefore this work is concerned with
the replacement of existing metallic gear with composite material gear in order to
make it lighter and increasing the efficiency of mechanical machines with the aid of
computer aided engineering.
2.7 DESIGN OF ACOUSTICAL OPTIMIZED BEVEL GEARS USING

MANUFACTURING SIMULATION
Christian brecher et al [7] The comparison of the measured and the

simulated TE showed that the FE-based tooth contact analysis ZaKo3D is capable of
giving a good agreement between simulations and testing. The requirement is that the
scatter of the topography is known and, if necessary, considered in the simulation.
The comparison of the simulation with the averaged topography and the simulation
with the consideration of all teeth showed difference of more than 50 %. Additionally,
the results lead to the concept that by applying a targeted topography scatter, it is
possible to reduce the TE respectively the excitation level.
Therefore, the method is applied for an exemplary gear set. Two variants are
investigated; a ground target topography is calculated and as well a variant with a
scatter in the topography deviations. The topography scatter is derived from a possible
lapping process, but can be also applied on purpose in the grinding process. By
applying the micro geometry scatter from tooth to tooth, the results of the TE
calculation show that the amplitudes of the tooth mesh frequencies decrease. In
parallel, the amplitudes of the frequencies in between the tooth mesh frequencies are
rising. The TE of the ground reference shows a tonal distribution.
15
2.8 STATIC & DYNAMIC ANALYSIS OF SPUR GEAR USING
DIFFERENT MATERIALS
M. Keerthi et al [8]The objective of the project is to reduce the stress

distribution, deformation and weight of spur gear by using composite materials in the
application of gear box. The designed composite spur gear is compared with the
existing gear materials, such as structural steel, gray cast iron and aluminum alloy.
The tool which is used to analyze the different spur gear materials is ANSYS. In this,
the analysis of torque loading and stress induced are to be performed for the materials
chosen. The final outputs of these analyses for all the materials are to be compared.
From this comparison, the stress induced, deformation and weight for composite spur
gear materials are to be less than that of the general spur gear materials.
It was concluded that the stress values are calculated for composite materials
is approximately same as compared to the structural steel, gray cast iron and
aluminum alloy. So from these analysis results, we conclude that, the stress induced,
deformation and weight of the composite spur gear is almost same as compared to the
structural steel spur gear, gray cast iron spur gear and aluminum alloy spur gear. So,
Composite materials are capable of using in automobile vehicle gear boxes instead of
existing cast steel gears with better results. The natural frequency of Structural Steel
Spur Gear varies from 2019.7 Hz to 6399.7 Hz. For Gray Cast Iron Spur Gear the
natural frequency varies from 1575.2 Hz to 4990.8 Hz, whereas for Aluminum Alloy
Spur Gear the natural frequency varies from 2003.8 Hz to 6353.2 Hz. The design is
safe since the frequencies obtained exceeded the natural frequency of the spur gear
(41.66 Hz).
2.9 DESIGN AND ANALYSIS OF CROWN PINION OF A

DIFFERENTIAL GEAR BOX FOR REDUCED NUMBER OF TEETH
TO IMPROVE TORQUE TRANSMITTED
Matthew D Brown et al [9] This paper gives a detailed approach to spiral
bevel gear design and analysis. Key design parameters are investigated in accord with
industry standards and recommended practices for use in a medium class helicopter.
A final gear design is proposed and analyzed to show that proper margins of safety
have been included in the design. Upon completion of the design phase of the gear,
analysis was conducted to ensure appropriate margins of safety had been implemented
into the design. Calculated values of Hertz stress and bending stress are less than the
16
allowable stresses as per AGMA standards. As a result, the stresses produced in the
gear teeth were acceptable, mitigating the risk of failure to the designed gear teeth.
2.10 TOOTH CONTACT ANALYSIS AND MANUFACTURE ON

MULTITASKING MACHINE OF LARGE-SIZED STRAIGHT BEVEL
GEARS WITH EQUI-DEPTH TEETH
Kazumasa Kawasaki et al [10] Large-sized straight bevel gears are widely
used in the plant of large-sized power generation when the gears have large size. The
tooth contact analysis of large-sized straight bevel gears with equi-depth teeth was
achieved and these gears were manufactured on a multitasking machine. For this
study, the mathematical model of straight bevel gears by complementary crown gears
considering manufacture on multitasking machine was proposed, and tooth contact
pattern as well as transmission errors of these straight bevel gears with modified tooth
surfaces were analyzed in order to clarify the meshing and contact of these gears.
Next, the numerical coordinates on the tooth surfaces of the bevel gears were
calculated and the tooth profiles were modeled using a 3DCAD system. Five-axis
control machines were utilized. The gear work was machined by swarf cutting using a
coated carbide end mill. After rough cutting, the gear-work was heat-treated and it
was finished based on a CAM process through the calculated numerical coordinates.
The pinion was also machined similarly. The real tooth surfaces were measured using
a coordinate measuring machine and the tooth flank form errors were detected using
the measured coordinates. As a result, the obtained tooth flank form errors were small.
In addition, the tooth contact pattern of the manufactured large-sized straight bevel
gears was compared with those of tooth contact analysis. As a result, there was good
agreement.
2.11 ACTUAL TOOTH CONTACT ANALYSIS OF STRAIGHT BEVEL

GEARS
Theoretically, spherical involutes are used as one of the base topographies for
straight bevel gears. Actual bevel gears, however, have deviations from their intended
topographies due to manufacturing errors, heat treatment deviations, and finishing
processes. Measuring the physical parts with coordinate measuring machines
(CMMs), this study proposes a new approach to capture such deviations. The
measured deviations from spherical involutes are expressed in form of a third-order
two-dimensional (2D) polynomial function and added to the base topography to
duplicate the geometry of the actual part; tooth thickness deviation is also accounted
17
for and corrected through changing the theoretical tooth thickness. The resultant
surfaces are then used to construct ease-off and surface of roll angle topographies and
to perform tooth contact analysis (TCA) and calculate motion transmission error (TE).
3 THEORETICAL CALCULATIONS
3.1 SPECIFICATIONS OF AN AUTOMOBILE DIFFERENTIAL
In order to find bending and contact stresses of bevel gears the
specifications of a bevel gear and the properties of four different materials were taken.
1. Maximum Power: - 46.97KW

2. Maximum Torque: - 182.5N/m@ 1500 -1800rpm
3. Maximum Speed: - 3200 rpm
3.2 SPECIFICATIONS OF BEVEL GEARS
1. Gear profile: - 20 degree

2. Pressure angle (α):- 20 degree
3. Bevel gear arrangement = 90 degree
4. Pressure Angle = 20 degree
5. Hub diameter = 50
6. Mounting distance = 100
7. Nominal shaft diameter = 25
8. Module (M) = 10
9. Number of teeth on gear = Z g =16
10. Number of teeth on pinion = Z p = 14
3.3 MATERIALS SELECTION
3.3.1 Phosphor Bronze 102
 Density = 8.85g/cm3
18
 Young modulus = 121 GPa
 Poisson’s ratio = 0.33
 Ultimate Tensile Strength = 650 MPa
 Ultimate Compressive Strength = 820MPa
 Yield Tensile Strength = 276 MPa
 Bulk modulus = 83.3 GPa
3.3.2 Chromium Nickel Steel Alloy
 Density = 7800 kg/m3

 Ultimate Tensile Strength = 680MPa
3.3.3 Structural steel

 Ultimate Tensile Strength = 460 MPa
 Bulk modulus = 166 GPa
3.3.4 Cast Iron

 Ultimate Tensile Strength = 4000MPa
19
3.4 SAMPLE CALCULATIONS WERE DONE FOR MATERIAL
PHOSPHOR BRONGE102 BY TAKING THE SPECIFICATIONS
 Density ( ρ ) =8.85 g/cm 3
 Young’s modulus (E)=121Gpa
1
 Poisson’s Ratio ( ) =0.33
m
 Ultimate tensile strength (σ us) =650Mpa
 Service factor (C s) =1.5
3.5CALCULATION OF BENDING AND CONTACT STRESS AT PITCH

ANGLE 400 FOR PB 102
POWER=46.97KW
SPEED=3200RPM
60 ×10 6 × P
Torque transmitted by gears ( M t ¿=
2 πN
60 ×10 6 × 46.97
M t= =140165.76 N / MM
2 π ×3200
Pitch diameter ( D p) = M × Z p
10 ×14=140 mm
2Mt
Tangential Force ( Pt ) =
Dp
2× 140165.76
140
Pt =2002.326 N
Radial Force ( Pr ) = Pt ×tanα × cosθ
Z p 14
θ= = =0.875
Z g 16
θ=tan −1 ( 0.875 ) =40.01
Pr =2002.368× tan 20 ×cos 41.18
Pr =548.52 N
20
Axial Force ( Pa ) = Pt ×tanα × sinθ
Pa=479.86 N
Cs
Effective Force ( Peff ) = × Pt
Cv
C s=1.5
π × Dp × N p
V=
60× 103
V =23.45m/ s
5.6
CONDITION: If V>20 Then C v =
5.6+ √ v
c v =0.53
Cs
Peff = × Pt
Cv
1.5
Pt = ×2002.368
0.53
Peff =5601.23
Beam Strength ( Sb ) = M × b × σ b × π × Y 1− [ b
AO ]
Peff =m× b ×σ b × π ×Y 1−
[ b
Ao ]
0.912
Y =0.154−
z'
' Z
Z=
cosθ
'
Z =18.6
y=0.1049
AO = (
√
AO =106.3 mm
D p 2 Dg 2
2
) +( )
2
2
By substituting all the values in the above equation we get σ b =64.30 N /mm w
Ultimate tensile stress (Sut) = 650N/mm2

Permissible Bending Stress = 40% of Sut
21
σ bu 141.67
Factor of safety (FOS) = =
σ bw 64.30
Factor of safety = 2.2
0.75× b ×Q × D p × K
Wear Strength ( Sw ) =
COSθ
Z×Zg
Q=
Z g × Z p × tan θ p
Q=1.1328
2
Sw =0.75× 50 ×1.1328 ×140 ×σ c × sinα ×cosα
[ 1 1
+
E p Eg ]
2
Sw =0.01820 σ c
2
Pt =0.01820 σ c
2002.368
σ c2 =
0.0182
2
σ c =11.13 N / mm
The remaining calculations for different materials are done by using graphical
user interface (GUI) developed by using PHP Hypertext pre processor.
A graphical user interface (GUI) is developed to do the number of iterations in
the preliminary stage of Design of Bevel Gears.
3.6 INTRODUCTION TO PHP
PHP started out as a small open source project that evolved as more and more
people found out how useful it was. Rasmus Lerdorf unleashed the first version of
PHP in 1994.
 PHP is a recursive acronym for "PHP: Hypertext Preprocessor".

 PHP is a server side scripting language that is embedded in HTML. It is used
to manage dynamic content, databases, session tracking, even build entire e-
commerce sites.
 It is integrated with a number of popular databases, including MySQL,
Postgre SQL, Oracle, Sybase, Informix, and Microsoft SQL Server.
 PHP is pleasingly zippy in its execution, especially when compiled as an
Apache module on the UNIX side. The MySQL server, once started, executes
even very complex queries with huge result sets in record-setting time.
22
 PHP supports a large number of major protocols such as POP3, IMAP, and
LDAP. PHP4 added support for Java and distributed object architectures
(COM and CORBA), making n-tier development a possibility for the first
time.
 PHP Syntax is same as C-language.
3.7 COMMON USES OF PHP

 PHP performs system functions, i.e. from files on a system it can create, open,
read, write, and close them.

 PHP can handle forms, i.e. gather data from files, save data to a file, through
email you can send data, return data to the user.
 You add, delete, modify elements within your database through PHP.
 Access cookies variables and set cookies.
 Using PHP, you can restrict users to access some pages of your website.
3.8 CHARACTERISTICS OF PHP

Five important characteristics make PHP's practical nature possible −
 Simplicity
 Efficiency
 Security
 Flexibility
3.9 GUI DEVELOPED USING PHP HYPERTEXT PREPROCESSOR
Select File > New Project (Ctrl-Shift-N on Windows and Linux, ⌘-Shift-N on
Mac OS). Create a new PHP project named "wish list". When you create a PHP
project, it contains the index fileindex.php by default. For information on creating and
configuring a PHP project, see Setting up a PHP Project.
23
3.10 INTERFACE
Window to
enter input Window to display
parameters results
Figure 3.11 Developed Interface
3.11 Theoretical results obtained through PHP program.
3.11.1 Bending stress at pitch angle 200 for four materials.
24
Figure 3.12 Bending stress for PB102 Figure 3.13 Bending stress for Cr-Ni
STEEL
Figure 3.14 Bending stress for Structural

Figure 3.15 Bending stress for Cast Iron
Steel
25
Steel

Steel
26
Figure 3.20 Bending stress for PB102
Figure 3.21 Bending stress for Cr-Ni
Steel
Figure 3.22 Bending Stress for Structural

Steel
27
Steel

Steel
28
Figure 3.28 Bending stress for PB102
Figure 3.29 Bending stress for Cr-Ni
Steel
Figure 3.30 Bending Stress for Structural

Steel
29
4 SOLIDWORKS INTRODUCTION
4.1 INTRODUCTION
Solid Works is design automation software. In Solid Works, you sketch ideas
and experiment with different designs to create 3D models. Solid Works is used by
students, designers, engineers, and other professionals to produce simple and complex
parts, assemblies, and drawings.
Solid Works works the way engineers design and think and that is why it has
become successful so quickly. Engineers and drafters say that it is easy to learn and
gives them a model that they have complete confidence in manufacturing and know
that it will work, just by using the tools provided with this one piece of software.
Solid works is powerful. The figure 6.1 shows the solid works interface.
Figure 4.32 Solid works interface
 To start our projects select the sheet of paper shown. Notice there is another
sheet of paper on the right side panel and you can use that one as well.
 Select PART from the dialog box shown and SELECT OK. We are going to
make our FIRST part or drawing in Solid works. Basically solid works model
is made up of PART, ASSEMBLY, DRAWING.
 Next, we are asked for a PLANE to begin our sketch. According to our
drawing requirement, select the plane (as shown in the figure 6.2) in which the
30
part must be drawn. It should highlight and use your left mouse button to
select it.
Figure 4.33 plane selection
 Construct the drawing of required part and by giving the dimensions by smart
dimensioning.
 After constructing all the parts of the component, assemble the parts to obtain
the component. Further obtain the drawing of the component.
4.1.1 Intended Audience
This document is for new Solid Works users. In this document, you are
introduced to concepts and design processes in a high-level approach.
Solid Works Help contains a comprehensive set of tutorials that provide step-
by-step instruction on many of the features of Solid Works.
4.2 TERMINOLOGY
These terms appear throughout the Solid Works software and documentation as
shown in the figure 6.3.
 Origin: Appears as two blue arrows and represents the (0, 0, 0) coordinate of
the model. When a sketch is active, a sketch origin appears in red and
represents the (0, 0, 0) coordinate of the sketch. You can add dimensions and
relations to a model origin, but not to a sketch origin.
31
 Plane: Flat construction geometry. You can use planes for adding a 2D sketch,
section view of a model, or a neutral plane in a draft feature, for example.
 Axis: Straight line used to create model geometry, features, or patterns. You
can create an axis in different ways, including intersecting two planes. The
Solid Works application
 Face: Boundaries that help define the shape of a model or a surface. A face is
a Selectable area (planar or non-planar) of a model or surface. For example, a
rectangular solid has six faces.
 Edge: Location where two or more faces intersect and are joined together.
You can select edges for sketching and dimensioning, for example.
 Vertex: Point at which two or more lines or edges intersect. You can select
vertices sketching and dimensioning, for example.
Table 4.1 Data used for preparing the Gear in Solidworks
Parameter Bevel gear

Pinion Gear
No. of teeth 14 16
Normal module 10 10
Pressure angle (deg) 20 20
Mounting distance 100 100
Nominal shaft diameter(mm) 90 90
Face Width (mm) 50 50
Hub diameter 50 50
Torque (N-m) 182.5
Power (K-w) 46.97 46.97
Speed (rpm) 3200

Contact force (N) 140165
During the gear design, the main parameters that would describe the designed
gear such as module, pressure angle, and number of teeth could be used as the
parameters to define the gear. Relation is used to express dependencies among the
dimension needed for defining the basic parameters on which the model is depends.
32
The gears with different geometric properties can be modeled from the existing model
by just varying the few parameters on which it depends. In this work, module,
pressure angle, numbers of teeth, mounting distance, and the face width of both the
gears are taken as input parameters. I used these parameters, in combination with its
features to generate the geometry of the Bevel gear and all essential information to
create the model. By using the relational equation, the accurate three dimensional
Bevel gear models are developed. The assembly of gear is done by consider the left
and right Bevel gear. Then the file is saved as IGES format. The proportions of gear
obtained from theoretical analysis have been used for preparing geometric model of
gear.
Figure 4.34 Bevel Gear Model prepared in Solidworks software
4.4 ASSEMBLY OF BEVEL GEAR
33
Figure 4.35 Bevel Gear Assembly
1. Import the two gears such that their axis is at an angle of 90 0 using
perpendicular mate.
2. Align the two gears according to their center distance using distance mate.
3. Align the teeth properly using coincident mate.
34
5 INTRODUCTION TO ANSYS SOFTWARE
5.1 INTRODUCTION
Welcome to the world of Computer Aided Engineering (CAE) with ANSYS
Workbench. If you are a new user, you will be joining hands with thousands of users
of this Finite Element Analysis software package. If you are familiar with the
previous releases of this software, you will be able to upgrade your designing skills
with tremendous improvement in this latest release.
In the Graphical User Interface (GUI) of ANSYS Workbench, the user can
generate 3-dimensional (3D) and FEA models, perform analysis, and generate results
of analysis. You can perform a variety of tasks ranging from Design Assessment to
Finite Element Analysis to complete Product Optimization Analysis by using ANSYS
Workbench. ANSYS Workbench, developed by ANSYS Inc., USA, is a Computer
Aided Finite Element ANSYS also enables you to combine the stand-alone analysis
system into a project and to manage the project workflow.
The following is the list of analyses that can be performed by using ANSYS
Workbench:
1. Design Assessment 10. Modal

2. Electric 11. Random Vibration
3. Explicit Dynamics 12. Response Spectrum
4. Fluid Flow (CFX) 13. Rigid Dynamics
5. Fluid Flow (FLUENT) 14. Static Structural
6. Harmonic Response 15. Steady-State Thermal
7. I.C. Engine 16. Thermal-Electric
8. Linear Buckling 17. Transient Structural
9. Magneto static 18. Transient Thermal.
5.2 STARTING ANSYS WORKBENCH 15.0
To start ANSYS Workbench 15.0, choose Start > Programs/All Programs >
ANSYS 15.0 > Workbench 15.0 from the Taskbar, refer to Figure 5.1. Alternatively,
you can start ANSYS Workbench by double-clicking on the Workbench shortcut icon
displayed on the desktop of your computer. After the necessary files are loaded and
35
licenses are verified, the Workbench window along with the Getting Started window
will be displayed on the screen, as shown in Figure 5.1.
Figure 5.36 ANSYS work bench Icon in Windows OS

The Getting Started window guides you to use the interface of ANSYS
Workbench effectively. To close this window, choose the OK button.
The Workbench window helps streamline an entire project to be carried out in

ANSYS Workbench 14.0. In this window, one can create, manage, and view the
workflow of the entire project created by using standard analysis systems. The
Workbench window mainly consists of Menu bar, Standard toolbar, the Toolbox
window, Project Schematic window, and the Status bar, refer to Figure 37. Various
components of the Workbench window are discussed next.
36
Figure 5.37 Interface of work bench
5.3 PROJECT SCHEMATIC WINDOW
The Project Schematic window helps manage an entire project. It displays the
workflow of entire analysis project. To add an analysis system to the Project
Schematic window, drag the analysis system from the Toolbox window and drop it
into the green-colored box displayed in the Project Schematic window, as shown in
Figure Alternatively, double-click on an analysis system in the Toolbox window to
include it in the Project Schematic window. You can also add an analysis system to
the Project Schematic window by using the shortcut menu displayed on right-clicking
in the Project Schematic window. The procedure of adding an analysis system by
using the shortcut menu is discussed later in this chapter.
In the Project Schematic window, when you click on the down arrow available
at the top right corner, a fly out is displayed with various options to close, float,
restore, minimize, and maximize the Project Schematic window, refer to Figure 5.3
37
Figure 5.38 Project Schematic Window
Each time you drag and drop an analysis system or an item into the Project
Schematic window, a system is formed. Each system consists of cells which are used
to carry out various tasks within a system. You can add more than one system in the
Project Schematic window by dragging and dropping them from the Toolbox window,
as per the requirement. After adding systems to the Project Schematic window, you
can share the data available in the cells of one system with the corresponding cells of
another system. A common example of systems sharing same kind of data among
various cells of different systems is shown in Figure 5.3
5.4 Static Structural Module
In ANSYS Workbench, you can invoke most of the Figure 39. The shortcut
menu displayed by right-clicking on the Geometry cell in the Project Schematic
window tools by using a shortcut menu displayed on right-clicking. The shortcut
menus displayed are context sensitive, that is, the context in the shortcut menus will
change depending upon the place where you right-click to invoke it. You can right-
click anywhere in the Workbench window to display a shortcut menu. Some of the
options in a shortcut menu display an arrow on their right. This arrow indicates that
one more menu will be displayed on choosing this option.
38
Figure 5.39 Static Structural Module
 Engineering data such as young’s modulus, density, poisons ratio is given to

the material
Figure 5.40 Selection of material
39
After importing the geometry the environment of contact and bending will be
seen like this.
Figure 5.41 Assembly for Contact Stress Figure 5.42 Bevel Gear for Bending
Analysis Stress Analysis
Meshing is done by taking sizing and in sizing coarse medium mesh is given
as shown in fig5.8
Figure 5.43 Assembly after Meshing Figure 5.44 Bevel Gear after Meshing
40
Moment for the pinion and frictionless support for the gear is given for contact
model as shown in fig.45 and 46. Fixed support is given to the hub of the gear and
tangential force of 2002.01N is given to one of the tooth of the gear as shown in
fig.47 and 48.
Figure 5.45 Friction less support Figure 5.46 Moment
Figure 5.47 Fixed support Figure 5.48 Tangential Force
5.4.1 Modal Analysis
Modal analysis was carried out on bevel gear to determine the deformations at
different frequencies.
5.4.2 Natural Frequency
Natural frequency is the frequency at which a system naturally vibrates once it

has been set into motion. In other words, natural frequency is the number of times a
system will oscillate (move back and forth) between its original position and its
41
displaced position, if there is no outside interference. The natural frequency is
calculated from the formula given below. The natural frequencies depend on stiffness
of the geometry and mass of the material.
F=
1
2π √ K
M
42
6 ANSYS RESULTS
6.1 INDUCED STRESSES
Bending Stresses and Contact stresses had been obtained using ANSYS
software.
6.1.1 Bending Stresses induced in Bevel Gear for Cast Iron
6.1.1.1 Bending Stresses at pitch angle 200

Bending Stresses obtained at 200 pitch angle are listed in the Table.6.1
Figure 6.49 von-Mises Stresses at 200 Figure 6.50 Max principal stress at 200
pitch angle pitch angle
Figure 6.51 Max shear stress at 200 pitch Figure 6.52 Normal stress at 200 pitch
angle angle
Table 6.2 Induced Stresses at 200 Pitch angle
Stress ANSYS Result in N/mm2

Von mises stress 41.54
Max principal stress 33.61
Max shear stress 23.2
43
Normal stress 12.41
6.1.1.2 Contact Stress at pitch angle 200

Contact Stresses at 200 pitch angle is listed in Table 6.2
44
Figure 6.53 von-Mises Stresses at 200 Figure 6.54 Max principal stress at 200
pitch angle pitch angle
Figure 6.55 Max shear stress at 200 pitch Figure 6.56 Normal stress at 200 pitch
angle angle
Table 6.3 Contact Stresses at 200 Pitch

angle
Stesss Value in N/mm2
von-Mises 73.57
Maximum 73.29
Principal Stress
Maximum Shear 38.30
Stress
Figure 6.57 Contact Pressure at 200 Normal Stress 47.91
6.1.1.3 Bending Stress At Pitch Angle 250
45
Figure 6.58 Von –Mises stress at 250 Figure 6.59 Max principal stress at 250
Figure 6.60 Max shear stress at 250 Figure 6.61 Normal stress at 250
Table 6.4 Bending Stresses at 250

Value in
Stress
N/mm2
Normal stress 14.60
6.1.1.4 Contact stress at pitch angle 250.

Contact Stresses obtained at 250 pitch angle are listed in the Table.6.4.
46
Figure 6.62 von –Mises stress at 250 Figure 6.63Max principal stress at 250
Table 6.5 Contact Stresses at 250
Stress Value in N/mm2
Normal stress 43.37
Contact Pressure 20.07
Figure 6.66 Contact Pressure at 250
6.1.1.5 Bending Stress at Pitch Angle 300
47
Figure 6.67 von Mises stress at 300 Figure 6.68 Max principal sress at 300
Figure 6.69 Maximum shear stress at 300 Figure 6.70 Normal stress at 30
0


Normal stress 12.56
48
Figure 6.71 von Mises stress at 300 Figure 6.72 Max principal stress at 300
Figure 6.73 Maximum shear stress at 300 Figure 6.74 Normal stress at 300
Max principal 59.17
stress
Normal stress 43.15
Figure 6.75 Contact force at 300
49
6.1.1.7 Bending Stress at Pitch Angle 350.
Figure 6.76 von –Mises stress at 350 Figure 6.77 Max principal stress at 350
obtained value in
Stresses N/ mm2
Normal stress 11.66
50
Max principal 35.70
stress
Normal stress 24.70
51
6.1.1.9 Bending Stress at Pitch Angle 400.
6.10 Bending Stresses at 400
Value in
Stresss
N/mm2
Normal stress 7.66
Bending Stresses obtained at 400 pitch angle are listed in the Table.6.9.
52
6.1.1.10 Contact stresses at pitch angle 400
Figure 6.89 von Mises stress at 400 Figure 6.90 Max principal stress at 400
Max principal 29.23
stress
Normal stress 21.48
Figure 6.93 Contact Pressure at 40 0
53
6.1.2 BENDING AND CONTACT STRESSES INDUCED IN BEVEL
GEAR FOR PB102
6.1.2.1 Bending Stress at pitch angle 200
Obtained value in
Stresses N/ mm2
Normal stress 19.24
54
6.1.2.2 Contact stress at pitch angle 200
Obtained
value in
Stresses N/ mm2
von mises stress 58.85
Normal stress 44.22
Figure 6.102 Contact force at 20 0
55
Obtained value in
Stresses N/ mm2
Normal stress 15.54
56
Value in
Stress
N/mm2
Max principal
stress 48.61
Normal stress 43.28
Figure 6.111 Contact force at 250 Contact Pressure 20.22
57
Figure 6.114 Max shear stress at 300 Figure 6.115 : Normal stress at 300
obtained value
Stresses in N/ mm2
Normal stress 15.19
58
Table 6.17 contact stress at pitch angle

300
obtained
value in N/
Stresses mm2
Normal stress 43.22
Figure 6.120 : Contact force at 300 Contact Pressure 16.51
59
6.1.2.7 Bending Stress at pitch angle 350.
Figure 6.121: von –Mises stress at 350 Figure 6.122 Max principal stress at 350
Table 6.18 Bending Stress at pitch angle 350

Value in
Stresses
N/mm2
Normal stress 15.54
60
Contact Stresses obtained at 350 pitch angle are listed in the Table.6.18
Figure 6.125 von –Mises stress at 350 Figure 6.126 Max principal stress at
350
Table 6.19 Contact stress at pitch angle
350
Value in
Stress
N/mm2
Normal stress 43.22
61
Value in
Stress
N/mm2
Normal stress 19.24
62
400
Value in
Stress
N/mm2
Normal stress 22.23
63
6.1.3 BENDING STRESS INDUCED IN BEVEL GEAR BY TAKING Cr-Ni
STEEL AS MATERIAL
64
Figure 6.139 von –Mises stress at pitch Figure 6.140 Max principal stress at pitch
angle 200 angle 200
Figure 6.141 Max shear stress at pitch Figure 6.142 Normal stress at pitch angle
angle 200 200
Value in
Stress
N/mm2
Normal stress 12.47

65
angle 200 angle 200
angle 200 200
200
Value in
Stress
N/mm2
Normal stress 43.49
Figure 6.147 Contact Pressure at pitch

angle 200

66
angle 250 angle 250
angle 250 250
Value in
Stress
N/mm2
Normal stress 14.34

67
Figure 6.152 von –Mises stress at pitch Figure 6.153 Max principal stress at
angle 250 pitch angle 250
Figure 6.154 Max shear stress at pitch angle Figure 6.155 Normal stress at pitch
250 angle 250

250
Value in
Stress
N/mm2
Normal stress 43.35
Figure 6.156 Contact Pressure at pitch angle
250
68

Value in
Stress
N/mm2
Normal stress 15.23
69
Figure 6.161 Max shear stress at pitch Figure 6.162 Normal stress at pitch
angle 300 angle 300
300
Value in
Stress
N/mm2
Normal stress 43.08
Figure 6.163 Contact Pressure at pitch Contact Pressure 15.91

angle 300
70
Value in
Stress
N/mm2
Normal stress 14.75
71
350
Table 6.29 Contact stress at pitch
angle 350
Value in
Stress
N/mm2
Normal stress 24.63
72
angle 400 angle 400
Value in
Stress
N/mm2
Normal stress 17.67
73
400 angle 400
400
Value in
Stress
N/mm2
Normal stress 22.02

400
74
6.1.4 BENDING STRESS INDUCED IN BEVEL GEAR BY
TAKING STRUCTURAL STEEL AS MATERIAL

angle 200 angle 200
angle 20 0
200
Value in
Stress
N/mm2
Normal stress 12.61
75
200
Table 6.33 Bending Stress at pitch
angle 200
obtained value
Stresses in N/ mm2
Normal stress 44.09
Figure 6.190 Contact Pressure at 200 Contact Pressure 17.90
76
angle 250 angle 250
angle 250 250
obtained
value in N/
2
Stresses mm
Normal stress 14.60
77
Contact Stresses obtained at 250 pitch angle are listed in the Table.6.34
250

Normal stress 44.09
78
obtained value
Stresses in N/ mm2
Normal stress 15.05
79
Figure 6.204 von –Mises stress at pitch angle Figure 6.205 Max principal stress at
300 pitch angle 300
300 angle 300
Table 6.36 Contact stress at pitch
angle 300
obtained value
Stresses in N/ mm2
Normal stress 43.15
80
6.10.7 Bending Stress at pitch angle 350
angle 350 angle 350
angle 350 350
obtained
value in N/
2
Stresses mm
Normal stress 15.05
81
6.10.8 Contact stress at pitch angle 350.
angle 350 angle 350
Stress va
Normal stress 24.85
Figure 6.217 contact pressure at 350
82
6.10.9 Bending Stress at pitch angle 400.
angle 400 400
obtained value
Stresses in N/ mm2
Normal stress 15.80
83
6.10.10 Contact stress at pitch angle 400.Contact Stresses obtained at 400 pitch angle
are listed in the Table.6.40.
Figure 6.222 von –Mises stress at pitch Figure 6.223 Max principal stress at pitch angle 400
angle 400
Figure 6.224 Max shear stress at pitch Figure 6.225 Normal stress at pitch angle 400
angle 400

Normal stress 22.10
Figure 6.226 contact pressure at 400
84
6.2 MODAL ANALYSIS OF BEVEL GEARS HAS BEEN CARRIED FOR
MATERIAL CAST IRON WHEN THEY ARE IN CONTACT.
6.11.1 Contact Stress Modal Analysis at Pitch Angle 200.
Deformations at different frequencies at pitch angle 200 is listed in table.6.41
Figure 6.227 Deformation 1 at 200 Figure 6.228 Deformation 2 at 200
85
TABLE 6.41
pitch angle 20
S.No Frequenc Deformatio
y n
1 427.45 17.066
2 483.89 22.89
3 605.14 19.98
4 735.59 18.15
5 1010.5 12.49
6 1176.5 19.11
6.11.2 Contact Stress Modal Analysis at Pitch Angle 250.
86
TABLE 6.42
S.No Pitch angle 25
87
Frequency Deformation
1 912.68 21.40
2 1024.4 29.26
3 1245.5 25.21
4 1427.4 19.54
5 1570.6 18.46
6 2239.8 24.31
6.11.3 Contact stress modal analysis at pitch angle 300.
88
TABLE 6.43
Pitch angle 30
Frequenc Deformatio
S.No y n
89
1 1858.1 27.19
2 2051.8 37.44
3 2165 18.50
4 2420.2 32.02
5 2841 29.52
6 3959.9 30.55
90
TABLE 6.44
Pitch angle 35
Frequenc Deformatio
S.No y n
1 3056.2 22.39
2 3266.9 33.59
3 3547.2 46.22
4 4070.4 39.27
5 4640.2 36.14
6 6101.2 37.77

MATERIAL PB 102 WHEN THEY ARE IN CONTACT
6.12.1 Contact Stress Modal Analysis at Pitch Angle 200
91
TABLE 6.46
S.No Pitch angle 20
92
Frequenc Deformatio
y n
1 315.12 15.50
2 358.79 21.32
3 439.62 18.27
4 526.13 16.58
5 723.52 11.36
6 844.16 17.54
93
TABLE 6.47
94
Pitch angle 25
Frequenc Deformatio
S.No y n
1 651.77 19.42
2 757.33 27.26
3 906.25 23.07
4 1019.3 17.88
5 1123.4 16.75
6 1604 22.31
95
TABLE 6.48
Pitch angle 30
Frequenc Deformatio
S.No y n
1 1364.5 24.61
2 1510.9 34.78
3 1544.5 16.92
4 1763.5 29.10
5 2027.2 26.98
6 2832.3 27.97
96
TABLE 6.49
Pitch angle 35
Frequenc Deformatio
S.No y n
1 2177.8 20.34
2 2393.1 30.48
3 2603 42.78
4 2966.7 35.53
5 3310.1 32.94
6 4361.9 34.60
97
MATERIAL Cr-Ni STEEL WHEN THEY ARE IN CONTACT.
98
TABLE 6.50
Pitch angle 20
Frequenc Deformatio
S.No y n
1 425.32 16.51
2 482.02 22.23
3 600.65 19.35
4 728.42 17.57
5 1000.8 12.08
6 1165.6 18.52
99
TABLE 6.51
S.No Pitch angle 25
100
Frequenc Deformatio
y n
1 907.91 20.70
2 1020 28.43
3 1236.5 24.41
4 1413.1 18.93
5 1555.3 17.85
6 2218.4 23.56
101
TABLE 6.52
S. No Pitch angle 30
102
Frequenc Deformatio
y n
1 1847.7 26.29
2 2041.7 36.36
3 2143 17.91
4 2403.3 30.99
5 2812.1 28.59
6 3921.3 29.59
103
TABLE 6.53
Pitch angle 35
Frequenc Deformatio
S. No y n
1 3024.6 21.67
2 3247.3 32.49
3 3527.9 44.87
4 4042.2 37.98
5 4592.8 34.98
6 6041.1 36.59

MATERIAL Cr-Ni STEEL WHEN THEY ARE IN CONTACT.
104
TABLE 6.54
105
Pitch angle 20
S. No frequency Deformation
1 426.25 16.46
2 484.07 22.35
3 599.03 19.34
4 722.82 17.55
5 993.5 12.05
6 1157.9 18.53
106
TABLE 6.55
107
Frequenc Deformatio
y n
1 909.43 20.63
2 1023.4 28.58
3 1233.8 24.37
4 1401.5 18.91
5 1543.4 17.79
6 2202.2 23.57
Deformations at different frequencies at pitch angle 300 are listed in table.6.56.
108
TABLE 6.56
Pitch angle 30
Frequenc Deformatio
S.No y n
1 1849.4 26.18
2 2045.9 36.53
3 2124.6 17.89
4 2399.1 30.91
5 2788.4 28.56
6 3891.1 29.58
109
TABLE 6.57
110

Pitch angle 35
Frequenc Deformatio
S.No y n
1 2997.7 21.60
2 3247.6 32.38
3 3531 45.03
4 4035.4 37.83
5 4553.5 34.91
6 5993.8 36.58

MATERIAL CAST IRON WHEN THEY ARE IN BENDING.
6.15.1 Bending stress modal analysis at pitch angle 200.
111
TABLE 6.58

Pitch angle 20
S.No Frequency Deformation
112
1 410.02 17.13
2 412.82 16.64
3 529.06 12.38
4 554.02 10.92
5 692.92 17.93
6 693.5 17.87
113
TABLE 6.59
Pitch angle 25
Frequenc Deformatio
S. No y n
1 878.06 21.58
2 886.63 20.95
3 936.59 13.60
4 1120.8 15.72
5 1396.6 22.59
6 1397.7 22.54
Deformations at different frequencies at pitch angle 300 are listed in table.6.60.
114
TABLE 6.60
115
Pitch angle 30
Frequenc Deformatio
S.No y n
1 1569.5 17.34
2 1782.2 27.65
3 1808.6 26.47
4 2234.6 20.62
5 2652.6 28.46
6 2654.9 28.13
116
TABLE 6.61
S.No Pitch angle 35
117
frequency Deformation
1 2421.6 21.62
2 3130.4 34.74
3 3183.9 32.43
4 3821.4 26.46
5 4372.5 35.21
6 4377.8 35.39

MATERIAL PB 102 WHEN THEY ARE IN BENDING.
118
TABLE 6.62
Pitch angle 20
Frequenc Deformatio
S.No y n
1 302.88 15.56
2 305.09 15.14
3 393.33 9.92
4 396.57 11.21
5 495.63 16.36
6 495.45 16.31
119
TABLE 6.63
Pitch angle 25
S.No
Frequenc Deformatio
120
y n
1 647.71 19.59
2 653.9 18.95
3 664.58 12.42
4 839.02 14.25
5 996.2 20.63
6 996.95 20.56
121
TABLE 6.64
Pitch angle 30
Frequenc Deformatio
S.No y n
122
1 1113.5 15.73
2 1310.4 25.07
3 1330.5 23.99
4 1669.5 18.80
5 1890.3 26.10
6 1892 25.67
123
TABLE 6.65
Pitch angle 35
Frequenc Deformatio
S. No y n
1 0 20.27
2 0 23.90
3 2.81e-004 21.97
4 6.67e-004 18.42
5 9.11e-004 23.95
6 1.15e-003 17.03

MATERIAL Cr-Ni STEEL WHEN THEY ARE IN BENDING
124
TABLE 6.66
Pitch angle 20
S. No
Frequenc Deformatio
125
y n
1 408.11 16.57
2 410.92 16.14
3 528.36 11.97
4 547.98 10.56
5 686.03 17.36
6 686.6 17.30
126
TABLE 6.67
127
Frequenc Deformatio
y n
1 874.24 20.87
2 882.29 20.26
3 926.22 13.15
4 1118.2 15.02
5 1382.3 21.87
6 1383.4 21.82
128
TABLE 6.68
Pitch angle 30
Frequenc Deformatio
S. No y n
1 1552.1 16.77
2 1772.6 26.74
3 1799 25.60
4 2228.6 19.95
5 2625.1 27.56
6 2627.4 27.22
129
TABLE 6.69
130
Pitch angle 35
S. No Frequency Deformation
1 2394.8 20.92
2 3112.2 33.59
3 3165.7 31.36
4 3809 25.62
5 4327.2 34.12
6 4332.5 34.25

MATERIAL STRUCTURAL STEEL WHEN THEY ARE IN BENDING
131
TABLE 6.70
Pitch angle 20
Frequenc Deformatio
S. No y n
132
1 409.27 16.52
2 412.15 16.09
3 532.29 11.92
4 542.41 10.53
5 680.05 17.33
6 681.07 17.27
133
TABLE 6.71
Pitch angle 25
Frequenc Deformatio
S.No y n
1 876.15 20.80
2 884.25 20.18
3 916.67 13.11
4 1126.4 15.13
5 1370.5 21.84
6 1371.5 21.78
134
TABLE 6.72
135
Pitch angle 30
Frequenc Deformatio
S. No y n
1 1536 16.71
2 1775 26.64
3 1801.7 25.50
4 2243.5 19.90
5 2601.7 27.54
6 2604.1 27.16
136
TABLE 6.73
Pitch angle 35
Frequenc Deformatio
S. No y n
137
1 2370.2 20.84
2 3113.6 33.45
3 3167.9 31.22
4 3830.2 25.63
5 4288.8 34.15
6 4293.9 34.17
6.10 VARIATION OF BENDING STRESSES WITH FIVE PITCH ANGLES

AND FOR FOUR MATERIALS
Variation of bending stresses with variation in pitch angle for the materials
Structural steel, Phospor bronze PB102, Cr-Ni Steel and Cast Iron were shown in Fig-
6.378,Fig-6.379, Fig-6.380 and Fig6.381 respectively.
STRUCTURAL STEEL
50
45
40
35 Theoritical Bending stress
Analytical Bending stress
30
Von mises stress
Stress[MPA]
25 Max principal stress

20 Max shear stress
Normal stress
15
factor of saftey
10
5
0
15 20 25 30 35 40 45
Pitch angle in degrees
Figure 6.419 Variation of stresses with pitch angle for material Structural Steel.
138
PB102
60
50
Theoritical Bending stress

40
stress,MPA
Analytical Bending stress

Von mises stress
Max shear stress
20 Normal stress
factor of saftey
10
0
15 20 25 30 35 40 45
pitch angle in deg
Figure 6.420 Variation of stresses with pitch angle for material PB 102.
CR-NI STEEL
50
45
40
35 Theoritical Bending stress
30 Analytical Bending stress
Von mises stress
stress
Max shear stress

20
Normal stress
15 factor of saftey
10
5
0
15 20 25 30 35 40 45
pitch angle
Figure 6.421 Variation of stresses with pitch angle for material Cr-Ni steel.
139
CAST IRON
45
40
35
Theoritical Bending stress
30 Analytical Bending stress
stress,MPA
25 Von mises stress

15 Max shear stress
Normal stress
10
5
0
15 20 25 30 35 40 45
pitch angle in deg
Figure 6.422 Variation of stresses with pitch angle for material Cast Iron.
6.11 VARIATION OF CONTACT STRESSES WITH FIVE PITCH ANGLES
AND FOR FOUR MATERIALS
Variation of contact stresses with variation in pitch angle for the materials
Structural steel, Phospor bronze PB102, Cr-Ni Steel and Cast Iron were shown in Fig-
6.378,Fig-6.379, Fig-6.380 and Fig6.381 respectively.
STRUCTURAL STEEL
80
70
60 Theoritical Contact stress
Analytical Contact stress
50
stress,MPA
Von mises stress

30 Max shear stress
20 Normal stress
pressure
10
0
15 20 25 30 35 40 45
pitch angle in deg
Figure 6.423 Variation of contact stresses with pitch angle for material Structural
Steel.
140
PB102
80
70
60 Theoritical Contact stress
50 Analytical Contact stress
stress,MPA
Von mises stress

30 Max shear stress
Normal stress
20 pressure
10
0
15 20 25 30 35 40 45
pitch angle in deg
Figure 6.424 Variation of contact stresses with pitch angle for material PB 102.
CR-NI STEEL
80
70
60
Theoritical Contact stress
50
stress,MPA
40 Von mises stress

Max principal stress
30 Max shear stress
Normal stress
20
pressure
10
0
15 20 25 30 35 40 45
pitch angle in deg
Figure 6.425 Variation of contact stresses with pitch angle for material Cr-Ni steel.
141
CAST IRON
80
70
60
Theoritical Contact stress
50
stress,MPA
40 Von mises stress

Max principal stress
30 Max shear stress
Normal stress
20
10
0
15 20 25 30 35 40 45
pitch angle in deg
Figure 6.426 Variation of contact stresses with pitch angle for material Cast Iron
6.12 VARIATION OF DEFORMATIONS WITH DIFFERENT
FREQUENCIES FOR FOUR MATERIALS AT FIVE PITCH ANGLES
Deformations obtained at different pitch angles studied and It was observed that
Phosphor Bronze PB102 and Cr-Ni Steel were with less deformation compared with
Structural Steel and Cast Iron.
pitch angle 20
25
20
Deformation
15 structural steel
cr-ni steel
pb 102
10 cast iron
0
200 400 600 800 1000 1200 1400
Frequency
Figure 6.427 Variation of deformations with different frequencies for four materials.
142
pitch angle 25
35
30
25
Deformation
structural steel
20
cr-ni steel
15 PB 102
cast iron
10
0
400 600 800 1000 1200 1400 1600 1800 2000 2200 2400
Frequency
Figure 6.428 Variation of deformations with different for four materials.
pitch angle 30
40
35
30
25 cr-ni steel
DEFORMATION
structural steel
20
PB 102
15 cast iron
10
0
1000 1500 2000 2500 3000 3500 4000 4500
FREQUENCY
143
pitch angle 35
50
45
40
35
static structural
DEFORMATION
30
cr-ni steel
25
pb 102
20 cast iron
15
10
5
0
1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
FREQUENCY
6.13 VARIATION OF FACTOR OF SAFTEY FOR FOUR MATERIALS AT
FIVE PITCH ANGLES.
Variation factor of safety based on contact stresses had been obtained. At 350
pitch angle factor of safety is maximum for all the four materials.
CONTACT STRESS
60
50
factor of saftey
40
PB102
30 CR-NI STEEL
CAST IRON
20 STRUCTURAL STEEL
10
0
15 20 25 30 35 40 45
pitch angle
Figure 6.431 factor of safety is increasing from pitch angle 200 to 350 and after 350 it
starts decreasing.
144
BENDING STRESS
8
6
factor of saftey
5
STRUCTURAL STEEL
4 Cr-Ni STEEL
PB 102
3 CAST IRON
0
15 20 25 30 35 40 45
pitch angle
Figure 6.432 Variation of factor of safety with pitch angle based on bending Stress
145
7 CONCLUSIONS
The present work deals with evaluating the bending and contact stresses in a pair of
bevel gears for five pitch angles and four different materials, The following
conclusions were drawn from the study.
(1) It was observed that von-mises stresses were decreasing with the pitch angle
from 200 to 350. At 40deg pitch angle von-mises stresses is increasing.
(2) At 350 pitch angle minimum stresses are obtained for material cast iron.
(3) Factor of safety was increasing up to350 and after 350 it starts decreasing up to
400 in contact stress analysis.
(4) It wass observed that, factor of safety was high for Cr-Ni STEEL based on
induced bending and contact stresses.
(5) From the stress analysis with different materials it was observed that Cr-Ni
steel is the best material based on factor safety. After Cr-Ni steel PB102 can
be considered.
(6) It was observed from modal analysis that deformations is increasing with
increase in pitch angle.
(7) The results obtained in ANSYS for bending and contact stresses are good in
agreement with theoretical results.
146
8 REFERENCES
[1] Abhijeet.v.patil , V.R.Gambhire and P.J.patil of TKIET warnanagar. “Analysis

of bending of bevel gear by FEM”, International journal of innovative research
in advanced engineering, IJIRAE vol1, Issue06,july-2014.
[2] Alfonoso Fuentes and Jose L.Iserte of UPCT spain. “Computerized design of
advanced straight and skew bevel gears produced by precision forging”,
ELSEVIER Issue, April-2011.
[3] Ratnadeepsinh M. Jadeja and Dipesh kumar M. Chauhan of R.K.university of

Rajkot, Gujarat. “Bending Stress Analysis of Bevel Gears” ,IJIRSET
vol2,Issue07,july-2013.
[4] N. Mohan raj and M. jaya raj of sri Krishna college of technology. Tamil nadu
“Design of Contact Stress Analysis in Straight Bevel Gear”, IJCER
VOL03,Issue04.
[5] Mayank bansal and Nidhi sindu of Noida I nternational university. G.B.Nagar.
“Structural analysis of composite material differential gear box
assembly”,IJERST, vol03,Issue-july2016.
[6] T.Loknadh and Dr.P.S.S.vasu. “Design of crown wheelgear of differential gear

box used in heavy vehicles for structural loads”, IJSETR, vol04, Issue07, july-
2015
[7] M.Keerthi,K.Sandhya and K.Srinivas of DVR&Dr.HS MIC college,AP. “Static

& Dynamic Analysis of Spur Gear using Different Materials” , IRJET, vol03,
Issue01,jan-2016.
[8] Emre turkoz and can ozcan of AKRO Engineering, Turkey. “Bevel Gear Tooth
Bending Stress Evaluation Using Finite Element Analysis”, AKRO Research
and Development,
[9] Nauman A. Siddiqui and K.M.Deen of NESCOM, Department of metallurgy and

material sciences, University of Punjab. “Investigating the Failure of Bevel
147
Gears in an Aircraft Engine”, ELSEVEIR,2013.
9 WEB REFERENCES
[01] www.anitsmecch.orgfree.com/Gears.php
[02] www.rajaroy.co.in
148
Contents
1 INTRODUCTION.....................................................................................................................1
1.1 DEFINITION OF GEARS........................................................................................1
1.2 CLASSIFICATION OF GEARS..............................................................................1
1.2.1 Gears for Parallel shafts....................................................................................1
1.2.2 Gears for intersecting shafts.............................................................................3
1.2.3 Gears for Skew Shafts........................................................................................4
1.3 BASIC GEAR TERMINOLOGY.............................................................................4
1.3.1 Pitch Circle........................................................................................................5
1.4 LAW OF GEARING................................................................................................6
1.4.1 Derivation of law of gearing..............................................................................7
1.5 BEAM STRENGTH OF BEVEL GEARS................................................................8
1.6 WEAR STRENGTH OF BEVEL GEARS...............................................................9
2 LITERATURE REVIEW....................................................................................................12
2.1 BENDING STRESSES OF BEVEL GEARS.........................................................12
2.2 BENDING STRENGTH OF BEVEL GEAR BY FEM..........................................12
2.3 COMPUTERIZED DESIGN OF ADVANCED STRAIGHT AND SKEW BEVEL
GEARS BY PRECISION FORGING......................................................................................13
2.4 BEVEL GEAR TOOTH BENDING STRESS EVALUATION USING FINITE
ELEMENT ANALYSIS.........................................................................................................13
2.5 DESIGN OF CONTACT STRESS ANALYSIS OF STRAIGHT BEVEL GEARS
14
2.6 STRUCTURAL AND MODEL ANALYSIS OF A COMPOSITE MATERIAL...14
2.7 DESIGN OF ACOUSTICAL OPTIMIZED BEVEL GEARS USING
MANUFACTURING SIMULATION....................................................................................15
2.8 STATIC & DYNAMIC ANALYSIS OF SPUR GEAR USING DIFFERENT
MATERIALS.........................................................................................................................15
2.9 DESIGN AND ANALYSIS OF CROWN PINION OF A DIFFERENTIAL GEAR
BOX FOR REDUCED NUMBER OF TEETH TO IMPROVE TORQUE TRANSMITTED16
2.10 TOOTH CONTACT ANALYSIS AND MANUFACTURE ON MULTITASKING
MACHINE OF LARGE-SIZED STRAIGHT BEVEL GEARS WITH EQUI-DEPTH TEETH
16
2.11 ACTUAL TOOTH CONTACT ANALYSIS OF STRAIGHT BEVEL GEARS....17
3 THEORETICAL CALCULATIONS...................................................................................18
149
3.1 SPECIFICATIONS OF AN AUTOMOBILE DIFFERENTIAL............................18
3.2 SPECIFICATIONS OF BEVEL GEARS...............................................................18
3.3 MATERIALS SELECTION...................................................................................18
3.3.1 Phosphor Bronze 102......................................................................................18
3.3.2 Chromium Nickel Steel Alloy...........................................................................18
3.3.3 Structural steel................................................................................................19
3.3.4 Cast Iron..........................................................................................................19
3.4 SAMPLE CALCULATIONS WERE DONE FOR MATERIAL PHOSPHOR
BRONGE102 BY TAKING THE SPECIFICATIONS..........................................................19
3.5 CALCULATION OF BENDING AND CONTACT STRESS AT PITCH ANGLE
400 FOR PB 102.....................................................................................................................20
3.6 INTRODUCTION TO PHP....................................................................................22
3.7 COMMON USES OF PHP.....................................................................................22
3.8 CHARACTERISTICS OF PHP..............................................................................23
3.9 GUI DEVELOPED USING PHP HYPERTEXT PREPROCESSOR.....................23
3.10 INTERFACE..........................................................................................................23
3.11 Theoretical results obtained through PHP program.................................................24
3.11.1 Bending stress at pitch angle 200 for four materials........................................24
4 SOLIDWORKS INTRODUCTION....................................................................................29
4.1 INTRODUCTION..................................................................................................29
4.1.1 Intended Audience..........................................................................................30
4.2 TERMINOLOGY...................................................................................................30
4.3 SOLID MODELING OF BEVEL GEAR...............................................................31
4.4 ASSEMBLY OF BEVEL GEAR............................................................................33
5 INTRODUCTION TO ANSYS SOFTWARE.....................................................................34
5.1 INTRODUCTION..................................................................................................34
5.2 STARTING ANSYS WORKBENCH 15.0.............................................................34
5.3 PROJECT SCHEMATIC WINDOW.....................................................................36
5.4 Static Structural Module.........................................................................................37
5.4.1 Modal Analysis................................................................................................40
5.4.2 Natural Frequency...........................................................................................40
150
6 ANSYS RESULTS..............................................................................................................42
6.1 INDUCED STRESSES...........................................................................................42
6.1.1 Bending Stresses induced in Bevel Gear for Cast Iron.....................................42
6.1.1.2 Contact Stress.........................................................................................................43
6.1.1.4 Contact stress at pitch angle 25..............................................................................45
6.1.1.5 Bending Stress at Pitch Angle 30............................................................................46
6.1.2 BENDING AND CONTACT STRESSES INDUCED IN BEVEL GEAR FOR PB102......52
6.1.2.2 Contact stress at pitch angle 200.............................................................................53
6.1.2.3 Bending Stress at pitch angle 25.............................................................................54
6.1.3 BENDING STRESS INDUCED IN BEVEL GEAR BY TAKING Cr-Ni STEEL AS
MATERIAL.......................................................................................................................62
6.1.4 BENDING STRESS INDUCED IN BEVEL GEAR BY TAKING STRUCTURAL STEEL AS
MATERIAL.......................................................................................................................72
151
6.10.7 Bending Stress at pitch angle 350.................................................................................78
6.10.8 Contact stress at pitch angle 35....................................................................................79
6.10.9 Bending Stress at pitch angle 40..................................................................................80
6.10.10 Contact stress at pitch angle 40..................................................................................81
MATERIAL CAST IRON WHEN THEY ARE IN CONTACT............................................82
6.11.1 Contact Stress Modal Analysis at Pitch Angle 20 0................................................82
6.11.2 Contact Stress Modal Analysis at Pitch Angle 25........................................................83
6.11.3 Contact stress modal analysis at pitch angle 30...........................................................85
MATERIAL PB 102 WHEN THEY ARE IN CONTACT.....................................................87
6.4 MODAL ANALYSIS OF BEVEL GEARS HAS BEEN CARRIED FOR MATERIAL Cr-Ni STEEL
WHEN THEY ARE IN CONTACT................................................................................................93
WHEN THEY ARE IN CONTACT................................................................................................98
6.14.2 Contact stress modal analysis at pitch angle 25.........................................................100
MATERIAL CAST IRON WHEN THEY ARE IN BENDING...........................................104
152
6.15.1 Bending stress modal analysis at pitch angle 20........................................................104
MATERIAL PB 102 WHEN THEY ARE IN BENDING....................................................109
WHEN THEY ARE IN BENDING...............................................................................................114
MATERIAL STRUCTURAL STEEL WHEN THEY ARE IN BENDING.........................120
6.10 VARIATION OF BENDING STRESSES WITH FIVE PITCH ANGLES AND
FOR FOUR MATERIALS...................................................................................................125
6.11 VARIATION OF CONTACT STRESSES WITH FIVE PITCH ANGLES AND
FOR FOUR MATERIALS...................................................................................................127
6.12 VARIATION OF DEFORMATIONS WITH DIFFERENT FREQUENCIES FOR
FOUR MATERIALS AT FIVE PITCH ANGLES...............................................................129
6.13 VARIATION OF FACTOR OF SAFTEY FOR FOUR MATERIALS AT FIVE
PITCH ANGLES..................................................................................................................131
7 7 CONCLUSIONS............................................................................................................133
8 REFERENCES..................................................................................................................134
9 WEB REFERENCES........................................................................................................135
153
LIST OF FIGURES
Figure 1.1 Spur gears................................................................................................................2

Figure 1.2 Helical Gears...........................................................................................................2
Figure 1.3 Herringbone Gears...................................................................................................2
Figure 1.4 Rack and Pinion.......................................................................................................2
Figure 1.5 Straight Bevel Gears................................................................................................3
Figure 1.6 Spiral Bevel Gears...................................................................................................3
Figure 1.7 Hypoid Gears...........................................................................................................4
Figure 1.8 Worm Gears............................................................................................................4
Figure 1.9 Basic Gear Terminology..........................................................................................5
Figure 1.10 Law of Gearing......................................................................................................7
Figure 3.1 Developed Interface...............................................................................................23
Figure 3.2 Bending stress for PB102......................................................................................24
Figure 3.3 Bending stress for Cr-Ni STEEL...........................................................................24
Figure 3.4 Bending stress for Structural Steel.........................................................................24
Figure 3.5 Bending stress for Cast Iron..................................................................................24
Figure 3.6 Bending stress for PB102......................................................................................25
Figure 3.7 Bending stress for Cr-Ni Steel...............................................................................25
Figure 3.8 Bending stress for Structural Steel.........................................................................25
Figure 3.9 Bending stress for Cast Iron..................................................................................25
Figure 3.10 Bending stress for PB102....................................................................................26
Figure 3.11 Bending stress for Cr-Ni Steel.............................................................................26
Figure 3.12 Bending Stress for Structural Steel......................................................................26
Figure 3.13 Bending stress for Cast Iron................................................................................26
Figure 3.16 Bending stress for Structural Steel.......................................................................27
Figure 3.20 Bending Stress for Structural Steel......................................................................28
Figure 4.1 Solid works interface.............................................................................................29
Figure 4.2 plane selection.......................................................................................................30
154
Figure 4.3 Bevel Gear Model prepared in Solidworks software.............................................32
Figure 4.4 Bevel Gear Assembly............................................................................................33
Figure 5.1 ANSYS work bench Icon in Windows OS............................................................35
Figure 5.2 Interface of work bench.........................................................................................36
Figure 5.3 Project Schematic Window....................................................................................37
Figure 5.4 Static Structural Module........................................................................................38
Figure 5.5 Selection of material..............................................................................................38
Figure 5.6 Assembly for Contact Stress Analysis...................................................................39
Figure 5.7 Bevel Gear for Bending Stress Analysis................................................................39
Figure 5.8 Assembly after Meshing........................................................................................39
Figure 5.9 Bevel Gear after Meshing......................................................................................39
Figure 5.10 Friction less support............................................................................................40
Figure 5.11 Moment...............................................................................................................40
Figure 5.12 Fixed support.......................................................................................................40
Figure 5.13 Tangential Force..................................................................................................40
Figure 6.1 von-Mises Stresses at 200 pitch angle....................................................................42
Figure 6.2 Max principal stress at 200 pitch angle..................................................................42
Figure 6.3 Max shear stress at 200 pitch angle........................................................................42
Figure 6.4 Normal stress at 200 pitch angle.............................................................................42
Figure 6.5 von-Mises Stresses at 200 pitch angle.....................................................................43
Figure 6.6 Max principal stress at 200 pitch angle..................................................................43
Figure 6.7 Max shear stress at 200 pitch angle........................................................................43
Figure 6.8 Normal stress at 200 pitch angle.............................................................................43
Figure 6.9 Contact Pressure at 200..........................................................................................43
Figure 6.10 Von –Mises stress at 250......................................................................................44
Figure 6.11 Max principal stress at 250...................................................................................44
Figure 6.12 Max shear stress at 250.........................................................................................44
Figure 6.13 Normal stress at 250.............................................................................................44
Figure 6.14 von –Mises stress at 250.......................................................................................45
Figure 6.15Max principal stress at 250....................................................................................45
Figure 6.18 Contact Pressure at 250........................................................................................45
Figure 6.19 von Mises stress at 300.........................................................................................46
155
Figure 6.20 Max principal sress at 300....................................................................................46
Figure 6.21 Maximum shear stress at 300...............................................................................46
Figure 6.25 Maximum shear stress at 300...............................................................................47
Figure 6.27 Contact force at 300.............................................................................................47
Figure 6.38 Max principal stress at 400..................................................................................50
Figure 6.39 Max shear stress at 400........................................................................................50
Figure 6.40 Normal stress at 400............................................................................................50
156
Figure 6.67 : Normal stress at 300...........................................................................................56
Figure 6.72 : Contact force at 300...........................................................................................57
Figure 6.73: von –Mises stress at 350......................................................................................58
157
Figure 6.91 von –Mises stress at pitch angle 200....................................................................62
Figure 6.92 Max principal stress at pitch angle 200.................................................................62
Figure 6.93 Max shear stress at pitch angle 200......................................................................62
Figure 6.94 Normal stress at pitch angle 200...........................................................................62
Figure 6.95 von –Mises stress at pitch angle 200....................................................................63
Figure 6.96 Max principal stress at pitch angle 200.................................................................63
Figure 6.97 Max shear stress at pitch angle 200......................................................................63
Figure 6.98 Normal stress at pitch angle 200...........................................................................63
Figure 6.99 Contact Pressure at pitch angle 200......................................................................63
Figure 6.100 von –Mises stress at pitch angle 250..................................................................64
Figure 6.101 Max principal stress at pitch angle 250...............................................................64
Figure 6.102 Max shear stress at pitch angle 250....................................................................64
Figure 6.103 Normal stress at pitch angle 250.........................................................................64
Figure 6.108 Contact Pressure at pitch angle 250....................................................................65
Figure 6.109 von –Mises stress at 300.....................................................................................66
Figure 6.110 Max principal stress at 300.................................................................................66
Figure 6.118 Max shear stress at 350.......................................................................................68
Figure 6.119 Normal stress at 350...........................................................................................68
158
Figure 6.124 Contact Pressure at 350......................................................................................69
Figure 6.148 Max principal stress at 250................................................................................75
159
Figure 6.160 Contact Pressure at pitch angle..........................................................................77
Figure 6.169 contact pressure at 350.......................................................................................79
Figure 6.171 Max principal stress at pitch angle 400..............................................................80
Figure 6.175 Max principal stress at pitch angle 40 0...............................................................81
Figure 6.177 Normal stress at pitch angle 40 0........................................................................81
Figure 6.178 contact pressure at 400.......................................................................................81
Figure 6.179 Deformation 1 at 200..........................................................................................82
160
Figure 6.216 Deformation 2 at 300.........................................................................................90
161
Figure 6.257 Deformation 1 at 250........................................................................................100
162
163
164
165
Figure 6.371 Variation of stresses with pitch angle for material Structural Steel..................125
Figure 6.372 Variation of stresses with pitch angle for material PB 102..............................126
Figure 6.373 Variation of stresses with pitch angle for material Cr-Ni steel.........................126
Figure 6.374 Variation of stresses with pitch angle for material Cast Iron...........................127
Figure 6.375 Variation of contact stresses with pitch angle for material Structural Steel.....127
Figure 6.376 Variation of contact stresses with pitch angle for material PB 102..................128
Figure 6.377 Variation of contact stresses with pitch angle for material Cr-Ni steel............128
Figure 6.378 Variation of contact stresses with pitch angle for material Cast Iron...............129
Figure 6.379 Variation of deformations with different frequencies for four materials..........129
Figure 6.380 Variation of deformations with different for four materials.............................130
Figure 6.383 factor of safety is increasing from pitch angle 20 0 to 350 and after 350 it starts
decreasing.............................................................................................................................131
Figure 6.384 Variation of factor of safety with pitch angle based on bending Stress...........132
166
LIST OF TABLES
Table 4.1 Data used for preparing the Gear in Solidworks.....................................................31

Table 6.1 Induced Stresses at 200 Pitch angle.........................................................................42
Table 6.2 Contact Stresses at 200 Pitch angle.........................................................................43
Table 6.3 Bending Stresses at 250...........................................................................................44
Table 6.4 Contact Stresses at 250............................................................................................45
6.9 Bending Stresses at 400.....................................................................................................50
Table 6.10 Contact Stresses at 400..........................................................................................51
Table 6.11 Bending Stresses at 200.........................................................................................52
Table 6.16 contact stress at pitch angle 300.............................................................................57
Table 6.17 Bending Stress at pitch angle 350..........................................................................58
Table 6.18 Contact stress at pitch angle 350............................................................................59
Table 6.26 6 Bending Stress at pitch angle 350.......................................................................68
Table 6.27 Contact stress at pitch angle 350...........................................................................69
167
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1 INTRODUCTION

1.1 DEFINITION OF GEARS

1.2 CLASSIFICATION OF GEARS

1.2.1 Gears for Parallel shafts

1.2.1.1 Spur Gears

Figure 1.3 Herringbone Gears Figure 1.4 Rack and Pinion

Herringbone gears are also known as Double Helical Gears. Herringbone

1.2.2 Gears for intersecting shafts

1.2.2.1 Straight Bevel Gears

1.2.3.1 Hypoid Gears

1.2.3.2 Worm Gears

Figure 1.7 Hypoid Gears Figure 1.8 Worm Gears

1.3.1.1 Addendum Circle

1.3.1.2 Dedendum Circle

Figure 1.9 Basic Gear Terminology

1.3.1.5 Full Depth

1.3.1.7 Diametral Pitch

Where d= pitch circle diameter

1.3.1.9 Circular Pitch

1.3.1.10 Gear Ratio

1.3.1.11 Pressure Line

1.3.1.12 Pressure Angle

1.3.1.13 Pitch Angle

Figure 1.10 Law of Gearing

1.4.1 Derivation of law of gearing

Substituting 2 and 3 in 1 we get,

V =O1 Q w1 cosα=O2 Q w2 cosβ … … .4

Consider similar triangles O1MP and O2NP as shown below,

Hence it is proved that velocity ratio is constant.

1.5 BEAM STRENGTH OF BEVEL GEARS

Where, δ ( S b )=¿ Beam strength of the elemental section (N)

From (c) and (d),

Substituting (e) and (f) in (a) we get

1.6 WEAR STRENGTH OF BEVEL GEARS

Ratnadeepnish M.Jadeja et al [1] Here in this paper after doing the

2.3 COMPUTERIZED DESIGN OF ADVANCED STRAIGHT AND SKEW

2.4 BEVEL GEAR TOOTH BENDING STRESS EVALUATION USING

2.5 DESIGN OF CONTACT STRESS ANALYSIS OF STRAIGHT BEVEL

2.6 STRUCTURAL AND MODEL ANALYSIS OF A COMPOSITE

B. Venkatesh et al. et al [6], obtained Von-Misses stress by theoretical and

2.7 DESIGN OF ACOUSTICAL OPTIMIZED BEVEL GEARS USING

Christian brecher et al [7] The comparison of the measured and the

M. Keerthi et al [8]The objective of the project is to reduce the stress

2.9 DESIGN AND ANALYSIS OF CROWN PINION OF A

2.10 TOOTH CONTACT ANALYSIS AND MANUFACTURE ON

2.11 ACTUAL TOOTH CONTACT ANALYSIS OF STRAIGHT BEVEL

1. Maximum Power: - 46.97KW

3.2 SPECIFICATIONS OF BEVEL GEARS

1. Gear profile: - 20 degree

3.3 MATERIALS SELECTION

3.3.1 Phosphor Bronze 102

3.3.2 Chromium Nickel Steel Alloy

 Density = 7800 kg/m3

3.3.3 Structural steel

 Density = 7850 kg/m3

3.3.4 Cast Iron

 Density = 7300 kg/m3

3.5CALCULATION OF BENDING AND CONTACT STRESS AT PITCH