Bending Geometry Factor For Profile Corrected Involute Gear Tooth With Trochoidal Fillet

S.P.Ganesan and G. Muthuveerappan 1 Combat Vehicles Research and Development Establishment DRDO Chennai-600054.
1

Machine Design Section

Mechanical Engineering Department IIT Chennai-600 036.

Keywords: Spur Gear, Profile Correction, Trochoid, Geometry Factor, Bending Stress.
ABSTRACT The profile of the fillet places a very important role on the actual fillet bending stress. The AGMA approximates the fillet curvature with a constant radius on its layout procedure whereas this paper evaluates bending stress in gear taking actual Trochoidal fillet generated by the rack cutter. The geometry factor for the uncorrected gear is calculated and compared with that of AGMA. The work is extended for the corrected gear considering a case where the cutter tooth depth is 2.25 times module and the cutter radius is 0.2 times the module. Actual gear stress is determined using Finite Element Method with loading both at the Tip Load (HPTC) and Highest Point of Single Tooth Contact (HPSTC). 1. INTRODUCTION For high power transmission like that used in Battle tank, which requires compactness and ability to transmit high torque with finite life for gears, which may in one way be achieved by using Epicyclic gear train and profile corrected gears. Hence in such critical areas the gear tooth stresses need to be exactly determined considering the actual gear tooth geometry with Trochoidal fillet. Alfred Lewis was the first person to calculate the bending stress in 1892 assuming gear tooth to be a uniform strength parabolic cantilever beam neglecting the radial component of force and the stress concentration at the fillet of gear tooth.

* Correspondence: email: jmvr@iitm.ac.in , Phone: 044 -2578535, fax: 044 -22578501

In this paper the advances made in Computational method using Finite Element Analysis and analytical method is used in evaluating the bending geometry factor for profile corrected spur gear taking exact Trochoidal fillet generated with rack cutters. The load applied at the tip of gear tooth as well as the load at the highest point of single tooth contact are considered in the present work to evaluate the Geometry factor. The complete gear profile is generated by a VC++ program and the stress correction factor is evaluated using ANSYS 6.0 FEA package. The J factor obtained for the standard gear is compared with AGMA [4] J factor and the work is extended to profile corrected gear.

2. GENERATION OF GEAR TROCHOID PROFILE:

The Fig 1 shows generation of Trochoidal fillet by the tip of the basic rack with a = 0 (sharp cutter). Coordinates of the trochoid are calculated using Analytical method as shown in Eq (1) to (7). The type of Trochoidal fillet changes with parameters of the cutter like type of cutter (Pinion or Rack), edge radius (a), addendum (b), pressure angle and profile correction required in the gear.
* ( ( )
2 rt 2 # !r # b " ' * % # ( !r # b " % ( & ) r !r # b " # rt 2

Fig 1: Generation of Trochoidal fillet.

2 rt 2 # !r # b " ' % r % &

, t $ tan
tan + $

#1

rt # !r # b "
2

Eq (1) Eq (2)

$ $ ,
'' f
t

rt 2 - a - cos

# 2 ar

sin

Eq (3)
t t

#1

* r t # a sin + ( R f ( )

' % % &

Eq (4) Eq (5)

$ . - ,
f f

f " f

x $ R y $ R

* Sin ( , * Cos (,

)
" f

Eq (6)

Eq (7)

3.

CALCULATION OF BENDING STRESS:

The theoretical bending stress according to Wilfred Lewis [1] formula is given by

1 th $

WT f * m *Y

Eq (8)

Modified Form factor (Y) is obtained by considering the gear tooth as a beam, fixed at one end and loaded at the other. Modified Form Factor calculated from the geometric layout of the gear tooth profile. The above Eq (8) doesnt include the stress correction effect. Considering the stress correction effect the Eq (8) is modified as W *K f => 1 $ WT 1 th $ T th f *m* J f * m *Y Where in which
Yc / t

Eq (9)

J$

1 $ * cos 0 a ' * 6h tan 0 a ' m*( %*( 2 / t % & ) cos 0 & ) t

Y Kt

Eq (10) Eq (11)

The gear parameter at the critical section like thickness(t), effective moment arm (h), radius of curvature (rf) are calculated analytically from the geometry of gear. And according to AGMA stress correction factor (Kt) is obtained from empirical relation arrived from experiments conducted by Dolan & Brohamer [3] for ! = 20 deg is given in Eq (12) as.

* t ' K te $ 0.18 - ( % ( )Rf % &

0.15

*t ' *( % )h&

0.45

Eq (12)

In this paper stress correction factor Kt is taken as the ratio of actual stress (obtained from the Finite Element Method using Ansys 6.0 package) to the theoretical stress from the Lewis Eqn.

Kt $

1 ansys 1 lewis

Eq (13)

The Eq (13) takes care of certain practical effects such as a) Effective stress concentration. b) Location of load. c) Size effect. d) End of tooth effect.

4.

FINITE ELEMENT ANALYSIS To determine the stress correction factor the actual stress in the gear tooth fillet and

the coordinate of the critical points at which it occurs are determined through Ansys 6.0 software. For solving the gear section is considered as a plain strain case. The surface and fillet profile generated using a particular cutter are made use of in Finite Element Analysis. The Rim thickness factor KB is taken as 1.0 and a backup ratio mB of 1.20 based on the Dragos [6] analysis of gear tooth bending fatigue strength so that the rim thickness doesnt have any effect on the bending strength of gear tooth. Fig 2 shows the meshing of the gear tooth with the Tip loading and Fig 3 shows the nodal stress plot in the deformed shape with maximum stress occurring at the Trochoidal fillet of the gear tooth.

5.

Fig 2: Meshing of Gear Tooth RESULTS AND DISCUSSION

Fig 3: Nodal Stress Plot in deformed shape

The Bending geometry factor are evaluated for profile corrected gear generated with rack type cutters , both conditions where the load being applied at the Tip of tooth and load being applied at the Highest point of single tooth contact. The Bending geometry factor according to AGMA (empirical relation of Kte) is calculated using the Flowchart in AGMA [5] and is compared with results obtained from analytical cum finite element approach (Ansys). Pinion with 20, 30, 40 teeth separately meshed with gears of various number of teeth ranging from 12 to 275 teeth where considered for analysis to evaluate the Bending Geometry factor with and without correction in the gear. Cutter specification: Tip radius Correction Tooth depth a = 0.20 times module X = 0.1, 0.2, 0.3 = 2.25 times module

This analysis is extended for Highest Point of Single tooth Contact (HPSTC) and Tip Load (HPTC). Fig 4 shows J factor obtained from the present method closely agreeing

Fig 4 J-Factor for uncorrected gear (Tip) with that of AGMA [5] value, for Tip Loading (HPTC) with a maximum deviation of 4%. Fig 5 shows J factor for corrected gear with HPTC loading. Fig 6 shows the J factor for profile corrected gear with HPSTC Loading. Fig 7 shows the comparison between HPTC and HPSTC Loading.

Fig 5 J-Factor for corrected gear (Tip)

Fig 6 J-Factor for corrected gear (hpsc)

Fig 7 HPSC & Tip Loading Comparison

6. PRACTICAL SIGNIFICANCE OF PAPER: i. The fillet radius is assumed as smooth for calculating the geometry factor in AGMA [4], where the actual shape of the trochoid is considered in this paper. ii. The cutter geometry generating the gear like cutter edge radius, profile correction, pressure angle and whole depth factor could be varied as per the as per the requirement for determining the Geometry factor of the Gear. iii. The latest advances made in the computational method is used in the evaluating the stress correction factor. NOMENCLATURE a b f h J Kt Kte KB m mB Rt , Rf r rt rf t w Wt x,y Y Z Cutter edge radius of rack cutter. Dist bet pitch line of cutter & centre of utter edge radius Face width Effective moment arm Bending Geometry factor Stress Correction factor Stress Concentration factor from Photoelastic method Rim thickness factor Module Backup ratio of the gear rim Radius vector of the trochoid and root fillet . Pitch circle radius of gear. Radius of trochoid Radius of curvature at the critical point Thickness at the critical section Width at the Critical section Tangential applied load Coordinates of the generated Trochoid Modified Lewis form factor Number of the Teeth in Gear wheel Bending stress Pressure angle Angle bet centre of gear tooth & centre of trochoid Angle bet radius vector and centre line of trochoid Angle bet the radius vector & tangent to trochoid

1b 2 . ,t +

Subscript c t p g Ansys Lewis REFERENCES

1.

Compressive tensile Pinion Gear from Ansys from Lewis Equation

Lewis, W., Investigation of the strength of gear teeth, Proc. of the Engineers Club, Philadelphia, PA, 1893, PP. 16-23.

2. Earle Buckingham, Analytical Mechanics of Gear Geometry, New York, Dover Publications, 1949. 3. Dolan , T.J. and Broghamer , E.L., A Photoelastic Study of the Stresses in Gear Tooth Fillets , University of Illinois, Engineering Experiment Station , Bulletin No. 335 , 1942. 4. AGMA information sheet 908-B89, 1995. Geometry factors for determining the pitting resistance fand bending strength of spur, helical and herringbone gear teeth. 5. AGMA information sheet 918-A93, 1995. A summary of Numerical Examples demonstrating the Procedures for Calculating Geometry Factors for spur and Helical gears. 6. Drago, R.J., An improvement in the Conventional Analysis of Gear Tooth Bending fatigue Strength, AGMA P224.24, and October 1982. 7. Merritt. H.E, Gear Engineering, Pitman press, Newyork, 1971. 8. Xiaogen Su, Donald R. Houser, Characteristics of trochoids and their application to determining gear teeth fillet shapes, Mechanism and Machine Theory, Volume 35 , 2000 , 291-304.