Design Of Locking Gear

Stress Analysis
There are two main types of stress on gear teeth that are meshed with each other, these two
types of stress are bending stress and contact stress.
Before calculating the stress following data is acquired from the ring gear of the flywheel
Table 1 Ring gear data

Description Ring Gear

No of teeth 96

Outer Diameter 245 mm

Pressure Angle 20°

Pitch Circle 240 mm

Root Circle 233.74 mm

Addendum 2.50 mm

Dedendum 3.12 mm

Working Depth 5.62 mm

Circular Pitch 7.85 mm

Base Circle 225.5 mm

Face Width 8 mm

Module 2.5 mm

Clearance 0.62 mm

Figure 1 Nomenclature of Gear

 = 20°
Figure 2 Meshed Gear tooth
showing Pressure angle

Bending stress
Bending stress in gears is a specific type of mechanical stress that occurs in the teeth of a gear
when it is subjected to a torque or a bending moment. This stress is a critical consideration in
gear design and analysis, as it directly affects the load-bearing capacity, wear resistance, and
overall durability of the gear teeth. Bending stress in gears is primarily caused by the bending
moment applied to the gear teeth as they transmit torque from one gear to another.
The bending stress on a gear tooth can be calculated with the help of Lewis Bending
Equation.

W t Pd
σ b=
Fƴ

where,
σb = Lewis Bending Stress
Wt = Tangential Force
Pd = Diametral Pitch
F = Face Width
Ƴ = Lewis form factor (From table 14-2 Shigley’s Book)

Table 2 Values of the Lewis Form Factor Y (These Values Are for a
Normal Pressure Angle of 20°, Full-Depth Teeth, and a Diametral
Pitch of Unity in the Plane of Rotation)

To calculate the Bending stress, the tangential force is to be calculated. The tangential load on
the spur gears is shown in the figure below.

Figure 3 Loading on Gear Teeth

The tangential force Wt can be calculated as:

Tp
Wt=
rp

where,
Tp = Torque of pinion
rp = pitch radius
The pitch radius is converted into pitch diameter i-e.
dp
r p=
2

Putting the values of rp in the eq we get

2T p
Wt=
dp

Where,
dp = pitch diameter which can be written as
Np
d p=
pd

Putting the values of dp in the above equation we get

2 pd T p
Wt=
Np

where,
pd = diametral pitch (inverse of module)
Np = No of teeth of pinion (No of teeth of pinion are 12)
Tp = Torque of pinion (Torque of pinion is 8 Nm)
pd = diametral pitch (inverse of module) can be calculate as
1
pd =
m
1
pd =
2.5 mm
pd =0.4 mm=0.0004 m

2∗0.0004∗8
Wt=
12

W t =0.00053 N

Now to calculate the bending stress

0.00053∗0.0004
σ b=
0.008∗0.245
 2
σ b=0.00108 N /m

Contact Stress:
Contact stress in gear teeth refers to the stress that occurs at the point of contact between the
teeth of meshing gears. It is a critical factor in the design and analysis of gears and is
primarily responsible for wear, fatigue, and overall gear tooth failure. Contact stress is
concentrated at the specific contact points between the mating gear teeth.

Contact Stress
The contact

Figure 4 Bending and Contact Stress on Gear Teeth

stress can be calculated by Hartzian Equations that is given by

σ c=
√ F
a.b
where,
σc = contact stress
F = Applied force between gear teeth
a = base circle radius (r b)
d
∴ rb = cosα (d = diametral pitch &α = pressure angle=20° mentioned ∈figure 2)
2
b = face width of gear
To calculate the contact stress first, the applied force on between the gear teeth must be
calculated. It is calculated through following set of equations and procedure.
Radius of flywheel = r = 0.12 m
Torque from stator to flywheel = T = 8 N m

The force (F) applied by the stator motor on the flywheel is:
T=r × F
T
F =
r
where,
 8 Nm
F = = 66.6 N
0.12 m
The r b = base circle radius can be calculated as
d
r b = 2 cosα
0.24
r b = 2 cos ⁡(20 °)

r b = 0.112 m
Now the required force is obtained the contact stress can be calculated as follows

σ c=
√ F
a.b

σ c=
√ 66.6
0.112∗0.008
σ c =272.63 Pa

Material Selection
On the basis of the above stress calculations the material is to be selected for the
manufacturing of the locking gear. Some of the material properties of different materials are
taken in consideration, the comparison of the properties of different materials are as follow.
Table 3 Comparison of Material Properties

Property Steel Copper Aluminum Brass Titanium

Yield Strength (MPa) 250 – 700 70 – 220 36 - 500 250 – 600 240 – 550

Elastic Modulus (GPa) 190 – 210 110 – 130 50 – 70 100 – 120 110 - 140

Poisson’s ratio 0.27 – 0.30 0.33 0.33 0.33 0.33

From the above table it is observed that according to the calculations of stress the most
suitable material is aluminum. Aluminum have many alloys of which the yield strength is
different. The lowest yield strength of the aluminum is of aluminum 1100. The properties of
aluminum 1100 is mentioned below

Table 4 Material Properties of Aluminum Alloy 1100

Property Aluminum Alloy (Aluminum 1100)

Yield Strength (MPa) 34.0

Elastic Modulus (GPa) 68.9

Poisson’s ratio 0.33

Aluminum Alloy 1100 is the most suitable material foe the locking gear design as it falls
under the theoretical stress calculated. The theoretical stress calculated is very less i-e. 272.63
Pa and the aluminum 1100 have the yield strength of 34 MPa which is the lowest among all
the materials that were taken consideration.