Design and Analysis of Gear

Design and Analysis of power transmitted gear assembled with shaft
CHAPTER 1
INTRODUCTION
In mechanical technique, transmission means appliance which is used as intermediary

mechanism between driving machine (e.g. of engine) and working (consumed) machine. The
role of transmission is transmitting of mechanical energy from main shaft of driving machine to
main shaft of working machine. The selection of transmission is limited by the price of complete
appliance, by working environment, by dimensions of the appliance, technical regulations, etc. In
mechanical engineering, so as in technique generally, mechanical transmissions are broadly used.
Mechanical transmissions are mechanisms which are used for mechanical energy transmitting
with the change of angle speed and appropriate change of forces and rotary torques. According to
the type of transmitting, mechanical transmissions could be divided into: transmissions gear
(sprocket pair), belt transmissions (belt pulleys and belt), friction transmissions (friction wheels)
and chain transmissions (chain pulleys and chain).
The power is transmitted from one shaft to the other by means of belts, chains and gears. The
belts and ropes are flexible members which are used where distance between the two shafts is
large. The chains also have flexibility but they are preferred for intermediate distances. The gears
are used when the shafts are very close with each other. This type of drive is also called positive
drive because there is no slip. If the distance is slightly larger, chain drive can be used for
making it a positive drive. Belts and ropes transmit power due to the friction between the belt or
rope and the pulley. There is a possibility of slip and creep and that is why, this drive is not a
positive drive. A gear train is a combination of gears which are used for transmitting motion
from one shaft to another. Gear drive is used for short distances.
1.1 Gears
Gears are also used for power transmission. This is accomplished by the successive engagement
of teeth. The two gears transmit motion by the direct contact like chain drive. Gears also provide
positive drive. Gears are wheel-like machine elements that have teeth uniformly spaced around
the outer surface. They are used in pairs and are a very valuable design tool. Gears are mounted
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on rotatable shafts and the teeth are made to mesh (engage) with a gear on another shaft. Gears
deliver force (torque) and motion (rpm) from one part of a machine to another. A gear driven by
another gear 3/4 its own size will rotate at 3/4 the speed of the drive gear and deliver 4/3 the
torque. Being able to control speed and torque by varying the number of teeth of one gear, with
respect to another (ratio), makes gears a valuable design tool. An automobile transmission is an
excellent example of how this principle is put to use in controlling vehicle motion.
There are four basic types of gears; spur, helical, bevel, and spiral bevel. Spur gears are the most
common. A spur gear has teeth that are uniformly spaced around the outer surface. The teeth are
aligned in a direction that is parallel to the gear axis. A spur gear is designed to mesh with
another spur gear on a parallel shaft. Spur gears impose only radial (perpendicular to axis) loads
on gear shafts as opposed to helical, bevel, and spiral bevel gears which impose both radial and
thrust (axial) loads on gear shafts. The profile of the contact surface of spur gear teeth is in the
form of an involute curve. An involute curve is the path that the end of a string takes when it is
being unwound from a cylinder. The shape is easy to manufacture and is an efficient way to
transmit power between two gear teeth because of the tendency to maximize rolling and
minimize sliding. The efficiency of spur gears is in the high 90% range and approaches that of
anti-friction bearings.
Gears can be manufactured out of steel, iron, bronze, and plastic. Steel is the most widely used
gear material. Many different alloys of steel can be used for gears ranging from low carbon, low
alloy to high carbon, high alloy grades. Low carbon, low alloy steels are used when low cost is
of prime importance. High carbon, high alloy grades are used when small size and high load are
the major design objectives. Gear steels come in grades 1, 2, and 3 as classified by the American
Gear Manufacturing Association (AGMA). Higher grade numbers represent higher quality steels
which are used for higher performing gears. Iron is good because of its castability and wear
characteristics. Bronze is good when friction is a concern. Plastic gears have good moldability
properties but have limited load carrying capacity.
Gears can be manufactured over a very wide size range. They can range from a fraction of an
inch in diameter to many feet in diameter. Gear tooth height can vary from .001 inch (200
diametral pitch) to 4.31 inches (1/2 diametral pitch). Metric tooth height sizes vary from .431
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millimeters (0.2 module) to 107.85 millimeters (50 module). Gear teeth are normally
manufactured with pressure angles of 14.5°, 20°, or 25°. As the pressure angle is made larger, the
teeth become wider at the base and narrower at the tip. This makes the teeth stronger and able to
carry more load but more apt to chip at the tip if not properly designed. Pinions with higher
pressure angles can be made with fewer teeth because of there being less danger of undercutting.
Undercutting is a narrowing of the bottom of the teeth when being manufactured. Lower pressure
angle teeth have a narrower base and carry less load than higher pressure angle teeth but the teeth
are wider at the tip and less apt to chip. Finally, lower pressure angle teeth mesh more smoothly
and quietly than higher pressure angle teeth because of having higher contact ratios. Contact
ratio is a measure of the average number of teeth in engagement at the same time during gear
operation.
Advantages:
1. It transmits exact velocity ratio.
2. It may be used to transmit large power.
3. It may be used for small center distances of shafts.
4. It has high efficiency.
5. It has reliable service.
6. It has compact layout.
1.1.1 Spur gear
Spur gear is a simplest type of gear having its teeth cut parallel to the axis of shaft on which the
gear is mounted. Spur gears are used to transmit the power between parallel shafts. The spur gear
has 98-99% operating efficiency. They are usually employed to achieve constant drive ratio.
Spur gears are the least expensive of all types for parallel shaft applications. Their straight teeth
allow running engagement or disengagement using sliding shaft and clutch mechanisms. Typical
applications of spur gears include automatic motor vehicle gearboxes, machine tool drives,
conveyor systems, electric motor gearboxes. The majority of power gears are manufactured from
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hardened and case-hardened steel. Other materials used include iron, brass, bronze, and polymers
such as polyamide (e.g. nylon). The merits of spur gear are easy to design, low maintenance and
economical to manufacture and they impose only radial load on the bearings.
Figure 1.1: Spur gear
Spur Gear Terminology:
Figure 1.2 shows the Spur gear schematic of principal terminology.
Figure 1.2: Spur Gear Terminology
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1. Pitch circle: Pitch circle is the imaginary circle that rolls without slipping with a pitch circle
of a mating gear.
2. Pitch Circle Diameter: The pitch circle diameter is the diameter of the pitch circle. It is also
known as pitch diameter.
3. Pressure angle: Pressure angle is the angle between the common normal at the point of tooth
contact and the common tangent to the pitch circle. The usual pressure angles are 14½° and 20°.
4. Pitch point: It is a common point of contact between two pitch circles.
5. Pitch surface: It is the surface of the imaginary rolling cylinder that the toothed gear may be
considered to replace.
6. Addendum: The addendum is the radial distance of a tooth from the pitch circle to the top of
the tooth.
7. Dedendum: Dedendum is the circle drawn through the bottom of the teeth. It is also called
“root circle”.
8. Addendum circle: It is the circle drawn through the top of the teeth and it is concentric with
the pitch circle.
9. Dedendum circle: It is the circle drawn through the bottom of the tooth. It is also called “root
circle”.
10. Base Circle: The base circle of involute gear is the circle from which involute tooth profiles
are determined.
11. Circular pitch: The circular pitch 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 denoted by Pc.
Pc = πd/T
 D = diameter of the circle
 T = No. of teeth on the wheel
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12. Diametral Pitch: It is the ratio of a number of teeth to the pitch circle diameter. It is
indicated by Pd.
Pd = T/d = π/Pc
Pc = πd/T
Where,
 T= No. of teeth,
 d= Pitch circle diameter.
13. Module: A module is the ratio of pitch circle diameter by m. m= d/T.
14. Clearance: Clearance is the difference between the dedendum of one gear and the addendum
of the mating gear.
15. Total Depth: Total depth is the radial distance between the addendum and the dedendum of
a gear. It is equal to the sum of addendum and dedendum.
16. Working Depth: It is the radial distance from the addendum circle to the clearance circle. It
is equal to the sum of the addendum of the two meshing gears.
17. Tooth thickness: Tooth thickness is the width of the tooth measured along the pitch circle.
18. Tooth space: Tooth space is the width of space between the two adjacent teeth measured
along the pitch circle.
19. Face of the tooth: It is the surface of the tooth above the pitch surface.
20. Flank of the tooth: The flank of the tooth is the surface of the tooth below the pitch surface.
21. Top land: The top land is the surface of the top of the tooth.
22. Face width: Face width is the width of the gear tooth measured parallel to its axis.
23. Profile: It is the curve formed by the face and flank of the tooth.
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24. Backlash: Backlash is the di

difference
fference between the thickness of a tooth and the width of a
tooth space on which it meshes.
1.2 Shaft
Shaft is a common and important machine element. It is a rotating member, in general, has a
circular cross-section
section and is used to transmit power. The sha
shaft
ft may be hollow or solid. The shaft
is supported on bearings and it rotates a set of gears or pulleys for the purpose of power
transmission. The shaft is generally acted upon by bending moment, torsion and axial force.
Design of shaft primarily involves iin
n determining stresses at critical point in the shaft that is
arising due to aforementioned loading. Other two similar forms of a shaft are axle and spindle.
Axle is a non-rotating
rotating member used for supporting rotating wheels etc. and do not transmit any
torque.
que. Spindle is simply defined as a short shaft. However, design method remains the same for
axle and spindle as that for a shaft.
Figure 1.3: Shaft
Standard sizes of Shafts:
Typical sizes of solid shaft that are available in the market are,
Up to 25 mm 0.5 mm increments
25 to 50 mm 1.0 mm increments
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Material for Shafts:
The ferrous, non-ferrous materials and non metals are used as shaft material depending on the
application. Some of the common ferrous materials used for shaft are discussed below.
Hot-rolled plain carbon steel: These materials are least expensive. Since it is hot rolled, scaling is
always present on the surface and machining is required to make the surface smooth.
Cold-drawn plain carbon/alloy composition: Since it is cold drawn it has got its inherent
characteristics of smooth bright finish. Amount of machining therefore is minimal. Better yield
strength is also obtained. This is widely used for general purpose transmission shaft.
Alloy steels: Alloy steel as one can understand is a mixture of various elements with the parent
steel to improve certain physical properties. To retain the total advantage of alloying materials
one requires heat treatment of the machine components after it has been manufactured. Nickel,
chromium and vanadium are some of the common alloying materials. However, alloy steel is
expensive. These materials are used for relatively severe service conditions. When the situation
demands great strength then alloy steels are used. They have fewer tendencies to crack, warp or
distort in heat treatment. Residual stresses are also less compared to CS (Carbon Steel).
Stresses in Shafts:
The following stresses are induced in the shafts:
1. Shear stresses due to the transmission of torque (i.e. due to torsional load).
2. Bending stresses (tensile or compressive) due to the forces acting upon machine elements like
gears, pulleys etc. as well as due to the weight of the shaft itself.
3. Stresses due to combined torsional and bending loads.
1.3 Bearings
Bearing is a component that ensures smooth rotation between the fixed support and the rotating
shafts. These components are made of high carbon alloy steels that can bear huge amount of
loads and rotate at high RPMs.
There are two types of bearing---Sliding contact bearing and rolling contact bearings. Sliding
contact has a fluid between the inner and outer race that ensures smooth rotation. Rolling contact
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bearings also known as ball bearings have a handful of tiny hardened steel balls or rollers
between the inner and outer race, these balls are super finished and have less friction compared
to the sliding contact bearings.
These bearing have two types of loads acting on them namely Radial and Axial loads. These
loads are calculated while making the gearbox. The outer race of the bearing is fitted into the
casing and the inner race to the shaft.
Figure 1.3: Roller contact bearing
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CHAPTER 2
LITERATURE SURVEY
A brief literature survey is conducted on design and analysis of gears with shaft. Based on the
literature survey, the design considerations for shaft and gear are considered.
2.1 A review on design of spur gear and shaft with its analysis
K Vigneshwaran and et al [1] studied the Experimental and analytical stress analysis of spur
gear. Gears are most powerful machine element to transmit the motion between rotating shaft. It
acts as a dominating transmission system from many years ago. In this work, a spur gear from
stone crusher machine is analysed using theoretical Lewis equation and Finite element analysis
method. Here, the bending stress on the spur gear is analysed since these stresses induced play a
vital role in gear life. The analysis presented the effect of gear material on induced bending
stress. Module is important parameter during modelling of spur gear.
Stephen K. Armah and et al [2] presented a Preliminary Design of a Power Transmission Shaft
under Fatigue Loading Using ASME Code. Power transmission shafting is a vital element of all
rotating machinery. A complete shaft design involves many iterative phases and fundamental to
this is the determination of preliminary dimensions of the shaft. This paper presents a
comprehensive fatigue analysis approach of determining the initial dimensions of a power
transmission shaft under fatigue loading based on American Society of Mechanical Engineers
(ASME) Standard B106.1M:1985. A countershaft running at a constant speed is designed using
this approach. Stress analysis at potential critical locations is conducted to determine the shaft
sizes. The sizes from these locations are then used to estimate the sizes at low stress locations.
Swapnil J. Patil and et al [3] conducted a Design and Vibration Analysis for Shaft with Gear
Mountings using Finite Element Analysis. This paper contains the study about design and
vibration analysis for automobile gearbox element shaft with gear using Finite Element Analysis
(FEA). Analysis includes the study of equivalent stress and displacement response of the
component. The three- dimensional finite element model is constructed in ANSYS. The model is
meshed and the boundary conditions with external loads are applied in ANSYS workbench. With
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the help of ANSYS software we find out the total deformation, equivalent stress which is
response for noise and vibration of shaft with gear mounting.
Dario Croccolo and et al [4] conducted a review on Practical Approach to Gear Design and
Lubrication. A review about the practical design of gears, their tolerances, and drawings is
presented in the paper in order to propose a guideline for the designer. All the proposed formula,
as well as the full methodology, has been used and in-field tested for several years in the
framework of gear design in the machine tool industry. The described tools may be regarded as a
comprehensive method to guide the engineer from the white paper to final design and gear
drawing, following the required steps for gear parameter calculation and verification.
Ignacio Gonzalez-Perez and et al [5] carried out a work on Modified geometry of spur gear
drives for compensation of shaft deflections. One of the greatest concerns of spur gears is the
edge contact of tooth surfaces that is caused by misalignment of the gear drive. Such a
misalignment is caused partially by the deflections of the shafts where the gears are mounted. As
a result of the edge contact a non favorable condition of bearing contact is achieved, providing a
high level of contact and bending stresses. An intensive research and many practical solutions
have been directed to modify the gear tooth surfaces in order to avoid edge contact. An
innovative procedure is proposed here for: (i) determination of the errors of alignment at the gear
drive caused by shaft deflections, (ii) incorporation of such errors of alignment in the generation
process of spur gears for compensation of shaft deflections, and (iii), determination of a
favorable function of transmission errors for the design load. A finite element model of a spur
gear drive including pinion and wheel shafts is used for the determination of the errors of
alignment along the cycle of meshing.
L. Radhakrishna and et al [6] investigated on design and manufacturing of gear trains. Research
is aimed at developing a mechanism using a gear train that can be used for lifting weights and
loads. For the purpose of driving load we made necessary calculations for achieving end results.
Paper reveals in designing relevant components for worthful works at higher expectations and
estimations. A thought of that made us to prepare a prototype to lift required loads with lesser
efforts. Paper sheaths Design calculations of various components stated and Manufacturing of
those elements.
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Huan Bai and et al [7] investigated a Dynamic Analysis of Gear–Shaft–Bearing Coupled System
Considering Bearing Waviness Defect. Using finite element and lumped parameter methods, a
gear-shaft-bearing coupled vibration model was developed for a single-stage gear transmission
system considering bearing waviness, bearing clearance, time-varying transmission error
excitation, and shaft flexibility. Results show that at low and medium speeds range, the gear
transmission system with bearing waviness has large vibrational energy, leading to unstable
dynamic response, which would potentially cause a significant chaotic response. The dominant
frequencies of dynamic transmission error for the gear transmission system with bearing
waviness are the ball passing frequency and its harmonic frequency.
Arnell Justin Arul Prince and et al [8] reported a Design and Analysis of A Spur Gear with
Composite Material. This work is concerned with replacing metallic gear with composite
material so as to improve performance of machine and to have longer working life. Efforts have
also been carried out for modeling using 3D modelling software called SOLIDWORKS 2016
and finite element analysis of gears using ANSYS WORKBENCH R 2016. Composite gears
have been manufactured by stir casting, which is economical method. Composite gears offer
improved properties over steel alloys and these can be used as better alternative for replacing
metallic gears.
Ignacio Gonzalez-Perez and et al [9] investigated on Finite Element Model for Consideration of
the Torsional Effect on the Bearing Contact of Gear Drives. The finite element method is widely
applied for the determination of contact and bending stresses in gear drives. It is based on the
finite element model of the gear drive that is built by the discretization of the pinion and gear
teeth and usually does not take into account the supporting components of the gears, as shafts,
their bearings, or the gear case. Such components have an important influence in the formation
of the bearing contact due to their deformations under load. Recently, some improved models
have been proposed for finite element analysis of gear drives including their shafts. Those
models have allowed shaft deflections to be taken into account for the investigation of formation
of the bearing contact under load and its influence on bending and contact stresses. In this paper,
an enhanced finite element model that takes into account not only the shaft deflections but also
the torsional deformation of gear tooth surfaces due to torque transmission is proposed.
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Stuart H. Loewenthal [10] concluded in their paper titled “Design of Power Transmitting Shafts”
that Power transmission shafting is a vital element of all rotating machinery. This report
summarizes design methods, based on strength considerations, for sizing shafts and axles to
withstand both steady and fluctuating loads. The effects of combined bending, torsional, and
axial loads are considered along with many application factors that are known to influence the
fatigue strength of shafting materials. Methods are presented to account for variable-amplitude
loading histories and their influence on limited-life designs. The influences of shaft rigidity,
materials, and vibration on the design are also discussed.
2.2 Problem statement
For the proposed project, the design and validation of spur gear, shaft and key are considered
according to the problem statement mentioned below.
A shaft supported at the ends in ball bearings carries a straight tooth spur gear at its mid span and
is to transmit 7.5kW at 300rpm. The pitch circle diameter of gear is 150mm with 38 teeth and
pressure angle is 20˚. The distance between centre line of bearings and gear are 100mm each.
The shaft is made of steel with the allowable shear stress 45MPa.
2.3 Objective
The main objective of the present work is to design and analyze the gear used to transmit power.
Analyzing the gear enables to study the amount of stress induced on shaft and bearings. The sub-
objectives of the present work are as follows:
 To design the profile of spur gear and shaft and to predict the effect of gear bending.
 To develop 3D model of spur gear and shaft using CAD tool SOLIDWORKS.
 To develop and to determine bending stresses using ANSYS and compare the results with
conventional methods.
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CHAPTER 3
METHODOLOGY
3.1 Methodology
Based on the objective set for the present work, detailed methodology is as follows.
Step 1: Theoretical study and design of spur gear mounted on shaft.
Step 2: Designing the shaft and rectangular sunk key based on theoretical study of gear.
Step 3: Selection of bearings based on design study.
Step 4: Modeling of spur gear, shaft and key using CAD software – SOLIDWORKS.
Step 5: Analysis and validation of gear and shaft using ANSYS19.2 software based on
conditions considered for design.
3.2 Concept development
According to the problem statement of the present work, a concept is developed to design the
power transmission elements. Figure 3.1 shows the line diagram of spur gear mounted on shaft
supported with bearings.
Shaft
150mm
Ball Ball
bearing bearing
100mm 100mm
200mm
Figure 3.1: Line diagram of spur gear mounted on shaft
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CHAPTER 4
DESIGN DEVELOPMENT
4.1 Material Selection
Gear
Material: Steel
Type: Spur Gears
Reason:
 Low cost
 Ease of machining
 Internal damping
Shaft
Material: Steel (Low to medium carbon steel)
Reason:
 Has high modulus of elasticity

 Minimizes deflection as combination of bending moment and torque on rotating shaft
creates multi-axial stresses
Key
Material: Steel
Type: Rectangular sunk key
Reason:
 Material with ductile properties is used as keys are loaded in shear.
Bearing
Material: Steel
Reason:
 Softer
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 Good strength
 Machinability
 Corrosion resistance
 Can withstand boundary lubrication
 Can support high loads and high temperature
4.2 Detail design of power transmission elements
The detailed design of spur gear, shaft and rectangular key are carried out based on the
specifications considered in the problem statement.
4.2.1 Design of spur gear
Spur gears are the most common type of gears. They have straight teeth, and are mounted on
parallel shafts. Sometimes, many spur gears are used at once to create very large gear reductions.
Spur gear design is conducted according to the spur gear terminology.
Circular pitch, Pc =
Pc = = 12.4 ≈ 12mm
Diametral pitch, Pd =
Pd =
Pd = 0.2533mm
Module, m =
m = 3.95 ≈ 4mm
Pitch, P = πm = 12.6mm
Addendum, A = module
Addendum circle diameter, Ad = d + 2A
Ad = 150 + 2 x 4
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Ad = 158mm
Deddendum, D = 1.25m
D = 1.25 x 4 = 5mm
Deddendum circle diameter, Dd = d – 2D
Dd = 150 – 2x5
Dd = 140mm
Tooth depth/Whole depth, h = A + D
h = 9mm
Tooth thickness = = = 6mm
Power, P =
7.5x103 =
T = 238.7Nm
Tangential force on the gear, Ft =
.
Ft =
.
Ft = 3182.7N
Radial force on the gear, Fr = Ft tanα
Fr = 3182.7 x tan20˚
Fr = 1158.4N
Normal load acting on tooth of the gear, W =

α
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.
W=
W = 3387N
By lewis equation,
Tangential force on gear, Ft = σd Cv πbym
σd = allowable static stress = 220.6MPa for steel (from data hand book)
.
Cv = velocity factor =
.
π π .
v= = = 2.36m/s
.
Cv = = 0.564
. .
b = face width of gear
.
y = lewis form factor = 0.154 – for 20˚ involute system
.
y = 0.154 – = 0.13
⸫ Ft = σd Cv 𝜋bym
3182.7 = 220.6 x 0.564 x 𝜋 x b x 0.13 x 4
Hence, face width, b = 15.66 ≈ 16mm
4.2.2: Design of shaft
Since the gear is mounted at the centre of the shaft, maximum bending moment at the centre of
gear,
M=
.
M=
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M = 169.4Nm
According to normal stress theory,
Equivalent twisting moment, Te = √M + T
Te = √169.4 + 238.7
Te = 292.7Nm = 292.7 x 103Nmm
π
Twisting moment, T = x 𝜏 x d3
π
292.7 x 103 = x 45 x d3
d = 32.11 ≈ 32mm
Hence, diameter of shaft, d = 32mm
4.2.3: Design of rectangular key
w l
Length of key, l = 1.25d
l = 1.25 x 32
l = 40mm
Width of key, w =
w=
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Width of key, w = 8mm
Thickness of key, t =
t=
Thickness of key, t = 5.33 ≈ 6mm
The key has taper 1 in 100 on top side.
4.2.4: Selection of ball bearing
The bearings utilized in the design of the gear are ball bearings. Ball bearings use a retainer that
keeps the balls properly spaced around the raceway. The assumptions made in the computation
regarding the bearings were that the tangential forces were assumed to be equally distributed to
both bearings. Several factors were considered during the consideration of the bearing, such as
the diameter of the shaft, the dynamic loading and the static loading, in order to calculate the
bearing life.
The shaft supported with bearings at its ends and gear at the centre is considered as a simply
supported beam with centre load. Shear force diagram and bending moment diagram are
represented for simply supported beam with centre load.
W
A B
C
RA RB
l/2 l/2
W/2 +ve
- ve W/2 SFD
BMD
Wl/4
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Reaction forces at A and B represents the load acting at bearings.
Reaction force at A, RA = = = 1693.5N
Reaction force at B, RB = - =- = - 1693.5N
Bending moment, M = RA x or M = RB x
.
M= = = 169.4Nm
Bearing life:
If shaft rotates at 300rpm for 8hrs per day for 10 years,
Bearing life, Ln = 300 x 60 x 8 x 365 x 10
Ln = 525.6 x 106 revolutions
Ln = 525.6 million revolutions
Bearing life in terms of hours, Lh =
.
Lh = = 29200hours
Rated life of bearing, L10 =
from design data hand book, = 8.19 for Ln = 525.6 x 106 revolutions and n = 3 for ball bearings
L10 = (8.19) = 549.35 million revolutions
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CHAPTER 5
DESIGN MODELING AND FINITE ELEMENT ANALYSIS
Design modeling of assembly and each part are developed using CAD tool SOLIDWORKS
software. 2D models are developed based on the design specifications obtained. Detailed
drawing of each component helped to assemble the components precisely.
5.1 2D drawings
Detailed drawing of gear, shaft and key way developed using SOLIDWORKS software. Figure
5.1, 5.2 and 5.3 represents the 2D drawings of gear, shaft and rectangular key. Figure 5.4 shows
the 2D drawing of assembly.
Figure 5.1: 2D drawing of Gear
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Figure 5.2: 2D drawing of Shaft
Figure 5.3: 2D drawing of Rectangular key
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Figure 5.4: 2D drawing of assembly
5.2 3D models
2D models are converted to 3D models in SOLIDWORKS. Figure 5.5, 5.6 and 5.7 represents the
3D models of gear, shaft and key. Figure 5.8 represents the 3D model of assembly.
Figure 5.5: 3D model of Gear
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Figure 5.6: 3D model of Shaft
Figure 5.7: 3D model of Key
Figure 5.8: 3D model of Assembly
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5.3 Finite Element Analysis
Finite Element Method is the easy technique as compared to the theoretical methods to find out
the stress developed in gear and shaft. Therefore FEM is widely used for the stress analysis of
gear assembly. In this project, finite element analysis is carried out in ANSYS Workbench 15.0
to determine the maximum stresses for steel gear and shaft. Also the deformation is found out for
both the components.
5.3.1 Boundary conditions
Fixed support is applied on one end of shaft. Tangential force of 3182.7N is applied on the gear
tooth. Figure 5.9 shows the boundary conditions applied for gear assembly.
Figure 5.9: Boundary condition
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5.3.2 Meshing
After boundary conditions are applied, mesh is generated for the gear mounted on shaft. Figure
5.10 shows the mesh of gear assembly.
Figure 5.10: Meshing
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CHAPTER 6
RESULT AND DISCUSSION
6.1 Results
The spur gear is designed according to the problem statement considered and spur gear
terminology is utilized to determine the various factors to design the gear. The amount of power
to be transmitted is considered as 7.5kW. Based on the power, the tangential force on gear tooth
is obtained as 3182.7N and normal force on gear tooth is 3387N. The shaft diameter is
determined by considering the normal load acting on gear tooth. According to normal stress
theory, the bending moment and twisting moment of shaft are calculated and hence diameter of
the shaft is determined. Rectangular sunk key is designed according to the standards available in
the design data handbook. With the load obtained, reaction forces and bending moment acting on
the shaft supports are determined. Using the reaction forces, the required ball bearings are
selected and bearing life is determined.
6.2 Discussion for results obtained on Finite Element Analysis
6.2.1 Static Analysis
a) Stress distribution
For a given specimen (gear assembled with shaft) Von-misses stress and strain are applied. The
stress and strain distributed across the model are obtained. Maximum stress and strain are plotted
as shown in figure 6.1 and 6.2. The maximum stress and strain can be observed at the base tooth
of gear element. The maximum value of stress obtained is 112.59MPa and a maximum value of
strain is 0.00058579.
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Figure 6.1: Von-Misses stress distribution
Figure 6.2: Von-Misses strain distribution
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b) Deformation
Gear element is subjected for total deformation and obtained the maximum deformation value of
0.13891mm. Figure 6.3 represents the deformation of assembly.
Figure 6.3: Deformation
Table 6.1 represents the results obtained using finite element analysis.
Table 6.1: Finite element analysis results
Parameters Result values

Von-Mises Stress 112.59MPa
Von-Mises Strain 0.0005857
Deformation 0.13891mm
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6.2.2 Modal Analysis
Modal analysis is an important tool for understanding the vibration characteristics of mechanical
structures. It converts the vibration signals of excitation and responses measured on a complex
structure that is difficult to perceive, into a set of modal parameters which can be straightforward
to foresee. The modal analysis calculates natural frequencies and mode shapes of the designed
model.
The natural frequency and mode shapes of the given design are calculated by using modal
analysis and the results are shown below.
Mode 1: Figure 6.4 shows the mode 1 shape for the given assembly at the excitement frequency
of 798.91Hz and maximum deformation of 31.619mm.
Figure 6.4: Modal Analysis of Mode 1 shape
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of 1432Hz and maximum deformation of 19.845mm.
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CHAPTER 7
CONCLUSION
The problem of determining stress induced on the spur gear assembled with shaft is of prime
importance. The problem is addressed analytically by designing the profile of spur gear, shaft
and key and predicted the bending moment, respectively. Finite Element Analysis is the right
choice for analyzing the design stress distribution over the gear profile.
The results presented in this study are analyzed using ANSYS 15.0 workbench software and are
concluded to be the right choice for the analysis.
The numerical results presented are believed to be quite accurate.
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Design and Analysis of power transmitted gear assembled with shaft

In mechanical technique, transmission means appliance which is used as intermediary

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1. It transmits exact velocity ratio.

2. It may be used to transmit large power.

3. It may be used for small center distances of shafts.

4. It has high efficiency.

5. It has reliable service.

6. It has compact layout.

1.1.1 Spur gear

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Figure 1.1: Spur gear

Spur Gear Terminology:

Figure 1.2 shows the Spur gear schematic of principal terminology.

Figure 1.2: Spur Gear Terminology

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4. Pitch point: It is a common point of contact between two pitch circles.

 D = diameter of the circle

 T = No. of teeth on the wheel

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 d= Pitch circle diameter.

13. Module: A module is the ratio of pitch circle diameter by m. m= d/T.

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24. Backlash: Backlash is the di

Figure 1.3: Shaft

Standard sizes of Shafts:

50 to 100 mm 2.0 mm increments

100 to 200 mm 5.0 mm increments

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Material for Shafts:

The following stresses are induced in the shafts:

3. Stresses due to combined torsional and bending loads.

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Figure 1.3: Roller contact bearing

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2.2 Problem statement

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Step 1: Theoretical study and design of spur gear mounted on shaft.

Step 3: Selection of bearings based on design study.

3.2 Concept development

Figure 3.1: Line diagram of spur gear mounted on shaft

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4.1 Material Selection

Type: Spur Gears

Material: Steel (Low to medium carbon steel)

 Has high modulus of elasticity

Type: Rectangular sunk key

 Material with ductile properties is used as keys are loaded in shear.

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4.2 Detail design of power transmission elements

4.2.1 Design of spur gear

Addendum circle diameter, Ad = d + 2A

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Deddendum circle diameter, Dd = d – 2D

Tooth depth/Whole depth, h = A + D

Tooth thickness = = = 6mm