Investigation of Spur Gear under Contact Load for Different Materials by using FEA Approach
Abstract
The spur gear is the most basic and is used in essentially all mechanical systems. There are numerous reasons why two pairs of gears can break, which leads to the failure of the gears. One of the primary forms of failure is caused by contact stresses generated during gear operation at high speeds. In this research, two pairs of spur gear are subjected to an analytical and finite element analysis with a focus on the stresses and deformation analysis for the two materials. 3D CAD model of spur gear pairs was modeled using ANSYS Design Modular, and then FEA analysis with different materials is conducted using ANSYS Workbench 16.0 and Analytical analysis is done by using Hertz Theory of contact stress. The results show that the maximum contact stresses calculated using the Hertz equation differ from those obtained using Finite Element Analysis by a very tiny, tolerable amount.. Contact stress for aluminum alloy by applying the same loading condition was recorded as 865.48 MPa while for gray cast iron it is 1034.6 MPa. Grey cast iron and aluminum alloy gears only slightly differ in overall deformation. It is concluded that aluminum alloy materials show better performance in overall operation as compared with gray cast iron hence it would be better for manufacturing