NATIONAL TRIBOLOGY CONFERENCE 24-26 September 2003

THE ANNALS OF UNIVERSITY DUNREA DE JOS OF GALAI FASCICLE VIII, TRIBOLOGY 2003 ISSN 1221-4590

349

3D CONTACT STRESS ANALYSIS FOR SPUR GEARS

Sorin Cnnu
University POLITEHNICA of Bucharest, Romnia scananau@meca.omtr.pub.ro

ABSTRACT
Non-conforming elastic bodies in contact, whose deformation remains sufficiently small for the linear small strain theory of elasticity to be applicable, are in 3D contact over a line (or lines), named contact line. Based on an exact geometry design of the involute gear tooth, a set of profile gears is obtained in order to calculate the 2D contact. A stress analysis was performed for CAD profiles results using the finite element procedure. The paper investigates the 2D analysis versus 3D analysis for stress in the root region of teeth. By this approach, is also investigated the influence of non-uniform load along contact line to the fillet stress. KEYWORDS: spur gear, contact, stress analysis.

1. INTRODUCTION
It is widely agreed that both experimental and theoretical analysis of spur gears can be performed using a 2D approach. This approach presumes that the load is uniform distributed along the tooth face (on a line parallel with shaft axis) and, in the most cases, only a single tooth is taking into account. Yet many 3D analysis of the spur gear have been accomplished in order to investigate if the development of fillet stress in the axis shaft direction can be ignored or what is the variation of this stress, [1,2,3]. In this paper will be study the differences for 2D and 3D approach used in spur gear design and stress analysis. The code for finite element analysis used is MSC- Nastran 2.1 The general hypotheses of the study are: 1. The geometry of the tooth and the gear is obtained using mathematical formulations for real cases of manufacturing; the profile of the tooth is an involute one and at the root region it has a trochoid form. 2. The geometry of the gear includes rim geometry with a solid geometry and defined ratio parameters of the rim thickness to the tooth height more than 2 to 1. 3. The number of the teeth tacking into account is three, in order to simulate the single and double pair teeth in contact, over the whole roll angle. 4. The load applied is modelled both for torque model and force loaded at the profile points.

2. GEOMETRY OF THE TOOTH

Geometry of the tooth is created using the mathematical formulation in [4]. There are 21 points on the developing involute profile and 5 points in the trochoid profile in the tooth fillet region. Table 1 gives the dimensions and mechanical properties of the studied gears. Number of teeth, z1/z2 Centre distance, a Pressure angle, n Module, m Diametral pitch, pn Working face width, b Young modulus, E Poissons ratio, Table 1 Spur gear data 17/31 [mm] 120 [deg] 20 [mm] 5 [mm] 15.7080 [mm] 40 [N/mm2] 2.07x105 0.32

3. FINITE ELEMENT GEAR MODEL AND ANALYSIS

The analysis of the gear stress in the fillet region was accomplish by means of the finite element method and software package of MSC Nastran 2.1 The first model used is a 2D model. With this model we will find the real points on the tooth profile where the single pair in contact change into a double pair of teeth in contact This way we find with a good approximation the loading diagram for the 21 points on the involute active profile. This first 2D model is shown in figure 1.

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NATIONAL TRIBOLOGY CONFERENCE 24-26 September 2003

THE ANNALS OF UNIVERSITY DUNREA DE JOS OF GALAI FASCICLE VIII, TRIBOLOGY 2003 ISSN 1221-4590

distribution were the mean value is the constant value at linear distribution. In figure 3 the 3D deformed model is represented.

Fig. 3 3D deformed model for gear under linear load at the edge line. Fig. 1 2D Model of spur gear mesh. For 2D case of study we aim another target: with this occasion we can find the Hertzian local deformations for every step in the mesh process for the 21 points and, simultaneously, the displacements of the tooth due to bending effect. These deformations and displacements are calculated in the following hypothesis: The contact interaction is treated as cvasistatic. The displacements are due to the contact algorithm and the type of finite elements used, without friction and only for rolling contact The dynamic effects are not taken into account In figure 2 it is represented a deformed model for the bending stress corresponding to the concentrated load applied (equivalent for a torque moment of 350 Nm) at the end of involute profile. This case corresponds to the linear distribution of load at the edge zone, were the flexibility is maximum. The results of deformations along the tooth, for this zone, are reported in figure 4.

Fig. 4 Edge tooth deformations along face width. It is obvious the end effect at the front and back zones of the tooth, along the face width. This could be explained by a smaller rigidity active in these zones. Also, it is obvious the symmetry of the tooth deformation along the face width. In figure 5 we can see von Mises stress distribution in the solid tooth. The shape of the distribution seems to be the same with the shape of deformations.

Fig. 2 2D deformed model and stresses for gear under load. Now we can study the stress distribution for the 3D model. For this case we are taking into account only the part of the gear that we found it sensitive at effects of the load applied. That means the model is a three teeth 3D model. Concerning the loads applied, two loads distribution were taking into account: the linear distribution along the tooth face width and triangular

Fig. 5 Von Misses stress in 3D model under linear load at edge line. It should be noticed that the stress distribution shows the same shape of the applied load distribution,

NATIONAL TRIBOLOGY CONFERENCE 24-26 September 2003

THE ANNALS OF UNIVERSITY DUNREA DE JOS OF GALAI FASCICLE VIII, TRIBOLOGY 2003 ISSN 1221-4590

351

except at the edge zone where the greater flexibility produces a local decrease of the stress value. In figure 6 and figure 7 it is reported the result of deformations and foot stress for a peculiar case of the triangular load distribution. Root stress 1 corresponds to the principal stress along the fillet tangency line. It should be noticed the difference in the shape distribution of deformation field and foot stress.

1.8 1.5 1.3

Complete constant linear Complete constant linear

1/0

1.0 0.8 0.5 0.3 1 2 3 4 5 6 7 8 9 10 11

Point number along tooth width
Complete triangular

m 28.0 24.0 20.0 16.0 12.0 8.0 4.0 0.0

Displacements

Fig. 8

4. CONCLUSIONS
1 2 3 4 5 6 7 8 9 10 11
Point number along tooth width
1. The stress distribution in the front plane for 3D model proves the same shape as the 2D model stress distribution, but the values are smaller with 10%-15%. 2. The stress distribution along the face width proves to have the same shape as the load distribution but NOT the same shape as the tooth edge deformations. 3. The stress increase significantly due to triangular load distribution, that means under nonuniform contact conditions in the meshing process.

Fig. 6 Displacements of the edge points along tooth face for gear under triangular load.
MPa

1000 800 600 400 200 0 1 2 3 4 5 6 7 8 9 10 11

Point number along tooth width

Foot stress 1

REFERENCES
1. Baret C. et al., 1994, 3D stress analysis of spur gears with profile errors and modifications using p-FEM models, International Gearing Conference, University of Newcastle upon Tyne, UK, pp. 149-164. 2. Cnnu S., 1998, Repartiia longitudinal a sarcinii pe lungimea liniilor de contact la angrenaje cilindrice cu dini drepi, PhD Thesis, Universitatea POLITEHNICA Bucureti. 3. Cnnu S., 1999, Contact stress analysis for Hertz nonconforming elastic contact of gears, U.P.B. Sci. Bull. Series D, Mech. Eng., Vol. 61, No. 3-4, pp. 243-250, ISSN 1454-2358. 4. Cnnu S., Rdulescu Gh., 2000, Analyse bidimensionnelle et deformations elastiques de la denture et le voile dun engrenaje droit, U.P.B. Sci. Bull. Series D, Vol. 62, No. 1, pp. 4550, ISSN 1454-2358.

Fig. 7 Von Misses stress field along tooth face for points at fillet region under triangular load. The results obtained for the linear to triangular load distribution are reported in figure 8, in terms of the ratio 1/0 , were 1 corresponds to the von Misses stress along the fillet tangency line and 0 represents the stress value at the centre of face width for linear load distribution value.