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Research Article | | Peer-Reviewed

The Design and Analysis of the Helical Gear in the Car Gear Box for the Slag Port Transfer

Anandan Kanagaraj*,  Senthilkumar Marakkanappatti Pandurangan,  Saravavan Durai,  Arunkumar Gopi
Published in International Journal of Mechanical Engineering and Applications (Volume 12, Issue 3)
Received: 3 January 2024     Accepted: 19 January 2024     Published: 20 August 2024
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Abstract

The design and analysis of helical gears with involutes profiles is the primary focus of this study. The most widely utilized gearing system in use today is the involutes gear profile. Power and torque are typically transmitted through them. When compared to other forms of transmission, the efficiency of power transmission via gears is extremely high. Bending and contact stress are the main causes of gear tooth failure. The current study examines helical gear, which has to do with slag transfer in the steel production sector. The most affected stress concentrated location of any set of gears in the slag port transfer car (SPTC) gear box is identified by examining the contact stresses for the current design set of gears. The high stress concentration gear set was redesigned with a constant (45mm) face width at various Helix angles (14, 15, 16, 17, 19^, 20 ̊, 25^, and 30 ̊) and a constant pressure angle (20). To calculate the contact stresses between two gears that are mating. The robust and cutting-edge solid modeling program AUTODESK FUSION 360 creates a three-dimensional solid model. The ANSYS Workbench module was utilized to do the numerical analysis. The outcomes of the workbench module for ANSYS. The current study is helpful in quantifying the previously mentioned factors, which aids in the safe and effective design of the helical gear in the SPTC Gearbox.

Published in International Journal of Mechanical Engineering and Applications (Volume 12, Issue 3)
DOI 10.11648/j.ijmea.20241203.12
Page(s) 71-80
Creative Commons

This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.

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Copyright © The Author(s), 2024. Published by Science Publishing Group
Previous article
Keywords

Power, Torque, Helical Angle, Pressure Angle, Gear, Fusion 360, ANSYS

1. Introduction
In all contemporary gadgets, gears are the most often utilized type of power transmission mechanism. The speed
[6]
or power between input and output can be adjusted using these toothed wheels. They are now widely accepted in a variety of applications and are heavily utilized in high-speed marine engines. The gear design of today's high- tech world has advanced to a very high level of perfection. With very little noise, vibration, or other undesired characteristics of gear drives, gears that can transmit incredibly large loads at extremely high circumferential speeds have been made possible by the design and production of precision-cut gears made from materials of high strength. Power is transferred from one shaft to another by way of the consecutive engagement of teeth in a gear, which is a toothed wheel with a unique tooth space of profile that allows it to mesh easily with other gears.
Gears work in pairs, with the bigger gear being referred to as the "gear" and the smaller one as the "pinion." Typically, the system serves as a torque converter and speed reduction while the pinion drives the gear. Up until now, gear makers have focused on failures brought on by high surface pressures, high root stresses and hardening cracks
[5]
they haven't looked at the relationship between mild wear and more serious types of damage
[8]
. Surface fatigue is a recognized issue that has been addressed with improved and purer materials, smoother surfaces, heat treatments, and other techniques.
There would be significant benefits if the wear distribution could be determined throughout the design process as this would provide insights into the intended product's functionality and longevity. While many researchers have studied gear wear, few have compared wear simulation studies in contrast to actual tests
[11]
. Typically, wear is handled carelessly, with crude approximations and no consideration for how wear may affect the gears' ability to function. A scale is typically used to represent the degree of wear during wear analysis of tested gears. Variations in mesh stiffness are caused by variations in the effective length of the line of contact, which is a result of the number of teeth in contact changing as the gears spin
[12]
.
2. Objective
The primary goal of this study was to employ several models to conduct static-structural analysis on a high- speed helical gear used in a gear box for automobile engines.
After comparing the findings from various analytical sections with the static analysis results, a determination has been made regarding the material
[3]
that should be used for the gear.
To calculate the bending stress applied to the helical gear 3-D solid model. Utilizing the ANSYS software suite
[2]
, the twisting stress is examined.
3. Current System and Methods
Pitting, or surface fatigue failure brought on by repeated exposure to high contact stresses
[1]
in the gear tooth, is one of the primary causes of gear tooth failures. This research aims to decrease the contact stress that frequently occurs on gears by adjusting the various face width values. By using the AGMA
[4] 
(American Gear Manufacturing Association) equation to calculate the contact stress and ANSYS for analysis, contact failure in gears can be anticipated. Solid Works software is utilized to construct the helical gear pair model, while ANSYS is employed for numerical analysis
[13]
. In the end, the ANSYS findings are shown and contrasted with theoretical values. Due of its lower weight, the face width of 21 mm, with a von-Mises stress of 493.27 MPa, was chosen for this investigation.
3.1. Techniques
AUTODESK FUSION 360 software was used to model the SPTC gearbox. Reverse engineering is used to get each component's dimensions from the construction site.
Basic equipment such as a Verniercaliper, steel rule, protractor, tape, and others are used in reverse engineering. Sketching is the process of processing data collection.
FUSION 360software is used to transform this sketch data into 3D objects. A created model of the helical gear assembly set is imported in the IGES format into the static structural module of ANSYS Workbench in order to perform contact analysis on the helical gear assembly.
With the exception of cases module 3 and module 4, the contact stress at the module 7 assembly - which consists of the output gear and second pinion shaft-exceeds the yield
[7]
strength limit.
Therefore, a safe design of the helical gear will be made by reducing the concentration of stress on stage 3.
The helical gear redesign of the module 7 gear set as detailed in the preceding section to maintain a steady module and pressure while changing the helix angle in order to lessen the concentration of stress on module 7.
3.2. Depiction of Helical Gears with Variable Helix Angles
The FUSION 360 models a redesign of a helical gear set with different helical angles.
Gears with different helix angles were developed and constructed in AUTODESK FUSION 360 in order to determine the range of helix angles for the redesign with the aid of finite element method of design.
 [7, 16]
.
After that, the assembled models are imported into ANSYS however the models are not correctly meshed due to the helix angle
[6]
below. As a result, the helix angle design above 14 degrees is appropriate and should be applied to the corresponding modeled parts.
Following meshing, the maximum pressures that can be achieved on a gear set's tooth are represented by post- processing.
3.3. Purpose
Autodesk Fusion 360 Designed 3D Model
Figure 1. 3DModel for Meshing Gear Set.
Figure 2. Simulation Diagram for Proposed System.
Figure 3. 3D Model for Module 4 Helical Gear.
Figure 4. Meshing Gear Set 3D Model.
Figure 5. Proposed System's Simulation Diagram.
Figure 6. Module 7 Helical Gear 3D Model.
Figure 7. Meshing Gear 3D Model Assign.
Figure 8. Meshing Gear 3D Model Assign.
Table 1. System Specifications.

System Description

Specifications for Hardware

Processor type: Intel

Core i5 RAM: 8 GB of 64-bit RAM

1 TB of storage

Display

20-inch color LCD

Specifications for software

Fusion 360 Autodesk

Workbench ANSYS 2021 R2

Fusion 360 Autodesk
Fusion 360 is a CAD/CAM
[15]
solution for teamwork in product creation that runs on the cloud.
Fusion 360 facilitates product ideation exploration and iteration as well as distributed product development team cooperation.
Fusion 360 is a comprehensive program that integrates mechanical design
[14]
manufacturing, and organic shape modeling.
3.4. Overview of Fusion 360
Fusion 360 is a CAD/CAM solution for teamwork in product creation that runs on the cloud. Fusion's technologies facilitate cooperation among members of a product development team as well as the investigation and refinement of product concepts. Fusion 360 is a concept-to-production toolkit that makes it quick and simple to explore design concepts. Fusion enables you to concentrate on the design, engineering, and construction of your goods. Utilize the modeling tools to add final touches and the sculpting tools to investigate shape.
You may swiftly iterate over design
[9]
concepts using these tools. After deciding on a design, you can make assembly to check that it fits and moves properly, or you can make photo-realistic renderings to confirm how it looks. Making your design a reality is the last step. Utilize the CAM workspace to design tool paths for your components' machining, or the 3D print workflows to quickly produce a prototypeCombination.
Additionally, 360 foster team collaboration in design teams for joint product creation. Since all of your designs are kept on the cloud, you and your group may always access the most recent information. Versions of your design are also tracked by Fusion while you work. With Autodesk A360, you can promote an older version to the most recent version and view each version in your web browser. Lastly, track design activities and share your designs
[10]
using Fusion and A360. Fusion 360 offers a hybrid environment that leverages the power of the cloud when appropriate and allows you to grant controlled access to your creations without having an Autodesk ID.
When appropriate, makes advantage of local resources. For instance, each time you save an updated version of your design, the design data is rendered and saved in the cloud, producing breathtaking visuals. While you are working locally on your machine and developing and revising designs, this is happening concurrently. This enables you to simultaneously utilize the power of the cloud and your computer. You study these Fusion 360 sections during this course. This course helps you learn how to create using Fusion and shows you how it can streamline your design workflows.
3.5. Helical Gear Parameters and Material Properties
The Parameters of Helical Gears
The helix angle of helical gears ranges from 7 to 30 degrees. These gears can operate at higher speeds and silently while transmitting greater power. The helix angle needs to match for the pinion and gear to mate. The normal module and the number of teeth on each gear and pinion are required in order to calculate the helical gear specifications. The table below lists the calibrated values for the SPTC helical gears.
Figure 9. Helical Gear Set Design.
Module 3 helical gear
Figure 10. Totaldeformation.
Figure 11. Equivalent stress.
Figure 12. Factor of safety.
Helical gear in Module 4
Figure 13. Total deformation.
Figure 14. Equivalent stress.
Figure 15. Factor of safety.
Helical Gear in Module 7.
Figure 16. Total deformation.
Figure 17. Equivalent stress.
Figure 18. Factor of safety.
Helical Gear with 14 Helix Angle in Module 7
Figure 19. Total deformation.
Figure 20. Equivalent stress.
Figure 21. Factor of safety.
Module 7, 15 Helix Angle Helical Gear Total
Figure 22. Total deformation.
Figure 23. Equivalent stress.
Figure 24. Factor of safety.
Module7, 16-HelixHelicalGearHelixAngle
Figure 25. Totaldeformation.
Figure 26. Equivalentstress.
Figure 27. Factorofsafety.
HelixAngleHelicalGearinModule7and17
Figure 28. Totaldeformation.
Figure 29. Equivalentstress.
Figure 30. Factorofsafety.
Figure 31. Stage I.
Table 2. Calibration of Helical Gear Parameters for Every Gear Set in the SPTC Gearbox.

S.No

Description

Stage 1

Stage 2

Stage 3

PINIO N

GEAR

PINIO N

GEAR

PINIO N

GEA R

1

Normal Module

3

4

7

2

Numberof Teeth

16

64

16

71

15

54

3

Helix Angle

16.26

14.835

14.983

4

Pressure Angle

20

20

20

5

Reference Diameter

50

200

66.21

293.79

108.70

391.30

6

Tip CircleDiameter

56

206

77.41

298.59

127.60

400.40

7

Root Circle Diameter

42.50

192.50

59.41

280.59

96.10

368.90

8

Clearance

0.75

1

0.35

9

Centre Distance

125

180

250
Figure 32. Stage II.
Figure 33. Stage III.
3.6. The Helical Gear's Material Properties
All of the aforementioned gears have the same material qualities. The table below lists the gear's properties in tabular form.
Figure 34. Factor of safety.
Figure 35. Factor of safety.
Table 3. Structural Steel's Mechanical and Chemical Properties.

ChemicalComposition

Properties

Mechanical Properties of Structural Steel

Carbon

0.22

Density

7850 g/m3

Tensile Strength (MPa)

320

Silicon

0.280

Specific heat capacity

486 J/(kg*K)

Young’s modulus (MPa)

210

Manganese

1.03

Electric resistivity

1.62*10-7 ohm*m

Elongation

38

Phosphorus

0.040

Electrical Resistivity

0.72 x 10-6Ω.m

Poisson’s ratio

0.3

Sulphur

0.050

Yield strength (MPa)

250
Table 4. Overall Result.

S.No

Analysis

Total deformation

Equivalent Stress

Safety Factor

Min

Max

Min

Max

Min

Max

1

Load on static structural 3 helical gear

0

0.086706

0.03179

605.46

0.14237

15

2

Impact on static structural 4 helical gear

0

0.07504

0.086404

355.61

0.2424

15

3

Impact on static structural 7 helical gear

0

0.026257

0.0010538

86.709

0.99413

15

4

Impact on static structural 7 helical gear 14 angle

0

0.016367

0.0033613

69.736

1.2361

15

5

Impact on static structural 7 helical gear 15 angel

0

0.017936

0.0019035

47.64

1.8094

15
Figure 36. Factor of safety.
4. Conclusions
ANSYS Workbench and AUTODESK FUSION 360 are used for analysis and modeling, respectively. When designing gears, the condition of stress is determined in part by pressure angle, helical angle, and face widths. The stress values obtained are smaller than their yield stress, as can be shown by looking at the analytical findings. The design is safe to use under working conditions, it may be inferred. Under safe operating conditions, the designs at Modules 3 and 4 are within permissible bounds; nevertheless, Module 7 demonstrates that the stresses exceeded the yield stress. Therefore, fusion 360 is used to redesign the helical gear at module 7 with a constant module, face width, constant pressure angle of 20, and changing helix angles (14, 15, 16, 17, 20, 25, and 30). The stresses for the examination of the remodeling gears are calculated at various helix angles while maintaining a constant face width. It can be observed that under the identical module and SPTC gear box operating circumstances, the contact stress at 14 degrees is comparatively lower.
Conflicts of Interest
The authors declare no conflicts of interest.
References
[1] "Stress Analysis of Gearbox," Pravin M., BR Kharde, and BR Borkar, IRACST, Volume: 2, Issue: 3, June 2012.
[2] "A review paper on design and analysis of helical gear using ANSYS, FEM & AGMA standards" by PrashantModi was published in the January 2017 issue of IRJET.
[3] Mechanica Confab, Volume: 2, No. 1, Jan. 2013, Pratik Gulaxea, N. P. Awate, "Design, Modeling& Analysis of Gear Box for Material Handling Trolley: A Review."
[4] "Contact Stress Analysis of Helical Gear by Using AGMA and ANSYS," S. SaiAnushaSatish Reddy, P. Chaska, and M. Manoj, IJSEAT, Volume: 2, Issue 12, Dec. 2014.
[5] A case study on various defects found in a gear system is presented by V. S. Panwar and S. P. Mogal in IRJET, Volume 02, Issue 03, and June 2015.
[6] A Jammal, Ch. "An Experimental Study On High Speed Helical Gears Misalignments and Dynamic Behavior under Random Loading" (GU, H Wang, R Li, Y Song, and YK Rong), ICMAE, 7th International Conference, 2016.
[7] "Stress Analysis of Helical Gear by Finite Element Method," Govind T. Sarkar, YL Yenarkar, and DV Bhope, IJMERR, Volume: 2, No. 4, October 2013.
[8] Process parameters optimization for helical gears precision forging with damage minimization: W Feng and L Hua, International Conference on Manufacturing and Distribution (ICDMA) -2010.
[9] "Modal Analysis of the Helical Gear of the Increasing Gear Box for Wind Generator," Z Yucheng and Wu Baolin, ICIMA, International Conference-2010.
[10] R. L. Norton, Machine Design: An Integrated Approach, Pearson Hall Inc., New Jersey, 1996.
[11] Yonatan, F., Spur Gear Teeth Variable Mesh Stiffness Using FEM, M. sc. thesis, Addis Ababa University's Department of Mechanical Engineering.
[12] Machine Design: An Integrated Approach by R. L. Norton, Prentice-Hall Inc., New Jersey, 1996.
[13] A Static Analysis of Composite Helical Gears Using Three-dimensional Finite Element Method, Vijayarangan, S. and Ganesan, N., Computers & Structures, 49, pp. 253-268, 1993.
[14] Maitra, G. M. (2014) Tata McGraw-Hill, New Delhi; Hand Book of Gear Design.
[15] Marappan, S. &Verkataramana, 2014, CAD Center, India, ANSYS Reference Guide.
[16] Finite Element Analysis of Stresses in Involutes Spur Helical Gear by Shreyash D. Patel, M. Sc. University of Texas at Arlington, 2019; thesis.
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    Kanagaraj, A., Pandurangan, S. M., Durai, S., Gopi, A. (2024). The Design and Analysis of the Helical Gear in the Car Gear Box for the Slag Port Transfer. International Journal of Mechanical Engineering and Applications, 12(3), 71-80. https://doi.org/10.11648/j.ijmea.20241203.12

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    ACS Style

    Kanagaraj, A.; Pandurangan, S. M.; Durai, S.; Gopi, A. The Design and Analysis of the Helical Gear in the Car Gear Box for the Slag Port Transfer. Int. J. Mech. Eng. Appl. 2024, 12(3), 71-80. doi: 10.11648/j.ijmea.20241203.12

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    AMA Style

    Kanagaraj A, Pandurangan SM, Durai S, Gopi A. The Design and Analysis of the Helical Gear in the Car Gear Box for the Slag Port Transfer. Int J Mech Eng Appl. 2024;12(3):71-80. doi: 10.11648/j.ijmea.20241203.12

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  • @article{10.11648/j.ijmea.20241203.12,
  author = {Anandan Kanagaraj and Senthilkumar Marakkanappatti Pandurangan and Saravavan Durai and Arunkumar Gopi},
  title = {The Design and Analysis of the Helical Gear in the Car Gear Box for the Slag Port Transfer
},
  journal = {International Journal of Mechanical Engineering and Applications},
  volume = {12},
  number = {3},
  pages = {71-80},
  doi = {10.11648/j.ijmea.20241203.12},
  url = {https://doi.org/10.11648/j.ijmea.20241203.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmea.20241203.12},
  abstract = {The design and analysis of helical gears with involutes profiles is the primary focus of this study. The most widely utilized gearing system in use today is the involutes gear profile. Power and torque are typically transmitted through them. When compared to other forms of transmission, the efficiency of power transmission via gears is extremely high. Bending and contact stress are the main causes of gear tooth failure. The current study examines helical gear, which has to do with slag transfer in the steel production sector. The most affected stress concentrated location of any set of gears in the slag port transfer car (SPTC) gear box is identified by examining the contact stresses for the current design set of gears. The high stress concentration gear set was redesigned with a constant (45mm) face width at various Helix angles (14, 15, 16, 17, 19^, 20 ̊, 25^, and 30 ̊) and a constant pressure angle (20). To calculate the contact stresses between two gears that are mating. The robust and cutting-edge solid modeling program AUTODESK FUSION 360 creates a three-dimensional solid model. The ANSYS Workbench module was utilized to do the numerical analysis. The outcomes of the workbench module for ANSYS. The current study is helpful in quantifying the previously mentioned factors, which aids in the safe and effective design of the helical gear in the SPTC Gearbox.
},
 year = {2024}
}

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  • TY  - JOUR
T1  - The Design and Analysis of the Helical Gear in the Car Gear Box for the Slag Port Transfer

AU  - Anandan Kanagaraj
AU  - Senthilkumar Marakkanappatti Pandurangan
AU  - Saravavan Durai
AU  - Arunkumar Gopi
Y1  - 2024/08/20
PY  - 2024
N1  - https://doi.org/10.11648/j.ijmea.20241203.12
DO  - 10.11648/j.ijmea.20241203.12
T2  - International Journal of Mechanical Engineering and Applications
JF  - International Journal of Mechanical Engineering and Applications
JO  - International Journal of Mechanical Engineering and Applications
SP  - 71
EP  - 80
PB  - Science Publishing Group
SN  - 2330-0248
UR  - https://doi.org/10.11648/j.ijmea.20241203.12
AB  - The design and analysis of helical gears with involutes profiles is the primary focus of this study. The most widely utilized gearing system in use today is the involutes gear profile. Power and torque are typically transmitted through them. When compared to other forms of transmission, the efficiency of power transmission via gears is extremely high. Bending and contact stress are the main causes of gear tooth failure. The current study examines helical gear, which has to do with slag transfer in the steel production sector. The most affected stress concentrated location of any set of gears in the slag port transfer car (SPTC) gear box is identified by examining the contact stresses for the current design set of gears. The high stress concentration gear set was redesigned with a constant (45mm) face width at various Helix angles (14, 15, 16, 17, 19^, 20 ̊, 25^, and 30 ̊) and a constant pressure angle (20). To calculate the contact stresses between two gears that are mating. The robust and cutting-edge solid modeling program AUTODESK FUSION 360 creates a three-dimensional solid model. The ANSYS Workbench module was utilized to do the numerical analysis. The outcomes of the workbench module for ANSYS. The current study is helpful in quantifying the previously mentioned factors, which aids in the safe and effective design of the helical gear in the SPTC Gearbox.

VL  - 12
IS  - 3
ER  -

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Author Information

  • Anandan Kanagaraj

    Department of Mechanical Engineering, P. S. V College of Engineering and Technology, Krishnagiri, India

    Contact Email

    http://orcid.org/0009-0007-6621-4297

  • Senthilkumar Marakkanappatti Pandurangan

    Department of Mechanical Engineering, P. S. V College of Engineering and Technology, Krishnagiri, India

    Contact Email

  • Saravavan Durai

    Department of Mechanical Engineering, P. S. V College of Engineering and Technology, Krishnagiri, India

    Contact Email

  • Arunkumar Gopi

    Department of Mechanical Engineering, P. S. V College of Engineering and Technology, Krishnagiri, India

    Contact Email

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  • Abstract
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  • Document Sections

    1. 1. Introduction
    2. 2. Objective
    3. 3. Current System and Methods
    4. 4. Conclusions
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  • Conflicts of Interest
  • References
  • Cite This Article
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