LYSIS OF PLASTICS GEAR FOR HEAVY DUTY METHO

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1 International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 7, July 2017, pp , Article ID: IJMET_08_07_013 Available online at aeme.com/ijm MET/issues.as asp?jtype=ijm MET&VType=8&IType= =7 ISSN Print: and ISSN Online: IAEME Publication Scopus Indexed DESIGN AND ANAL LYSIS OF PLASTICS GEAR FOR HEAVY DUTY APPLICATIONS BY FEA METHO OD T. Ramesh, K. Karthik, R. Ganesh Assistant Professor, Department of Mechanical Engineering, Veltech Dr.RR & Dr.SR University, Chennai, India ABSTRACT Gearing is one of the most critical components in mechanical power transmission systems. For drive designers, plastic gears offer several benefits ncluding design flexibility, reduced noise, and the ability to operate without lubrication. Other benefits include lower cost and weight, higher efficiency and chemical resistance. State-of-the- from ¼ to ¾ art gear has advanced to where plastic gears are now in drives ranging HP. The higher performance requirements for the drive were more complicated to make plastic gears work in heavy duty. Design effort was required to improve plastic gears performance. In this project plastic spur gear development to improve the bending stress, flexural strength and root strength by Geometric modification or Selective reinforcement under AGMA for power range of 2 to 4 HP. First plastic material was selected from various plastic materials based on the result of deflection and vonmises stress. Then selected plastic materials weree selective reinforced. Now Plastic gear model was created of ANSYS Mechanical APDL and then it was export to ANSYS Workbench calculate the contact stress and improve the impact strength. The solution of general problem by finite element method always follows an orderly step- by-step process. The loading conditions are assumed to be static. The elements were choosing solid 8 node185.the results of the 3D analyses in ANSYS was plotted. Finally compare with Low duty applications. Plastic gear limits can be defined in terms of contact stress and temperature for dry running gears. Key words: Reinforcement, Bending Stress, Flexural Strength and Root Strength. Cite this Article: T. Ramesh, K. Karthik, R. Ganesh. Design and Analysis of Plastics Gear for Heavy Duty Application ns by FEA Method. International Journal of Mechanical Engineering and Technology, 8(7), 2017, pp http: :// me.com/ijm MET/issues.a asp?jtype=i IJMET&VType=8&ITy ype=7 1. INTRODUCTION Gear transmission systems play an important role in many industries. The knowledge and understanding of gear behavior in mesh such as stress distribution, work condition and distortion is critical to monitoring and controlling the gear transmissionn system. Gears are often required to operate at high torque and speed, while remaining competitively priced and editor@iaeme..com

2 T. Ramesh, K. Karthik, R. Ganesh highly reliable. The gear materials used for the manufacture of gears depend upon the strength and service conditions like wear and noise etc. The gears maybe manufactured from metallic or non metallic materials. The cast iron is widely used for the manufacture of gears dueto its good wearing properties, Excellent machine ability and ease of producing complicated shapes by a sting method. The non metallic materials like wood, rawhide, compressed paper and plastics like Nylon, Acrylic and Polycarbonate etc are used for gears, especially for reducing weight and noise. The Nylon materials have high strength, good mechanical and abrasion resistance property, excellent wear resistance, resistant to most chemicals and self- lubricant. Polycarbonate materials have, high impact strength, good dimension stability and heat resistance. Since, Nylon and Poly carbonate have good properties as stated above the cast iron spur gears of sugarcane juice a chine are being replaced by plastic spur gears. The plastic material offer opportunities for substantial eight saving but not always are cost-effective over their cast iron counter parts. With the advance of Finite Element Analysis (FEA) software, many studies are now aimed at furthering the basic understanding of gears in mesh. The improved understanding of gear behavior will increase our ability to design high performance transmission systems to meet the need in various operating conditions. The Nylon materials have high strength, good mechanical and abrasion resistance property, excellent wear resistance, resistant to most chemicals and self- lubricant. Polycarbonate materials have, high impact strength, good dimension stability and heat resistance. 2. LITERATURE REVIEW The review mainly focuses on replacement of plastics spur gears with the Reinforcements fibers spur gear in the application of heavy duty. [1] This study method estimating for tooth root stresses caused by bending movements under running conditions the gear material used was cotton fiber plain woven cloth reinforced phenolic resin laminates. Paper-reinforced phenolic resin laminates, a commonly used material, was used as a control for comparison. The main dimensions of the gears were module 3 5 mm and tooth width 25 mm. First, accelerations of gears were measured under running conditions to estimate dynamic performance. Second, fracture tests of gear teeth were carried out under bending loads. Different fracture modes at Tooth roots for cotton fiber reinforced plastics and phenolic resin gears were observed. The fractures occurred at a high position from the tooth root in the case of the cotton fiberreinforced plastics gear because the cotton fiber-reinforced plastics had excellent cleavage and shear strength. This gear also had higher strength for tooth bending loads. Third, the mechanical properties of the gears were researched by tensile, bending, and shearing tests. It was clear that the cotton fiber reinforced plastics had excellent properties in cleavage fracture between laminates and shear strength. Finally, we proposed a design method for this gear, which considers the cleavage and shear strength. [2] This paper describes design and analysis of Spur gear. In the present work, it was proposed to substitute the metallic gear of sugarcane juice machine with plastic gears to reduce the weight and noise. For the purpose of two different types of plastic materials were considered namely Nylon and Polycarbonate and their viability are checked with their counterpart metallic gear (Cast iron). Based on the static analysis, the best plastic material was recommended for the purpose. Static analysis of a 3-D model has been performed using ANSYS Compared to Cast iron spur gears Nylon gears are suitable for the application of sugarcane juice machine application under limited load condition editor@iaeme.com

3 Design and Analysis of Plastics Gear for Heavy Duty Applications by FEA Method 3. SPECIFICATION OF THE PROBLEM In this project work it is future to substitute the metallic gear of heavy duty applications with plastic gears to reduce the weight and noise. For the purpose of two different types of plastic materials were considered namely Nylon and Polycarbonate and their viability are checked with their counterpart metallic gear. Based on the static analysis, The best plastic material is recommended for the purpose. A virtual model of spur gear was created in CATIA V5. Model is imported in ANSYS 10.0 for analysis by applying normal load conditions. After analyis a comparison is made among existing Cast iron spur gear. Based on the deflections and stresses from the analysis we choose the best different plastics materials spur gears Gear Design Gear is nothing but a toothed wheel which is useful to transmit power from one shaft to another shaft. They are suitable when two machine parts are nearer to each other. They give exact ratio of transmission of motion, slip cannot takes place between gears, and they are useful for high torque transmission. In spur gear teeth is parallel to axis of rotation. Spur gear transmits power from one shaft to another parallel shaft Materials for Gears The gear materials used for the manufacture of gears depend upon the strength and service conditions like wear and noise etc. The gears maybe manufactured from metallic or non metallic materials. The cast iron is widely used for the manufacture of gears due to its good wearing properties, excellent machine ability and ease of producing complicated shapes by casting method. The non metallic materials like wood, rawhide, compressed paper and plastics like Nylon, Acrylic and Polycarbonate etc are used for gears, especially for reducing weight and noise Specifications of Motor Power (P) = 3 kw = 3000watt Speed (N) = 1430 RPM Power (P) = 2*π*N*T / = (2*π*1430*T) / 60 Torque (T) = (3000*60)/ (2*π*1430) T= N-m T= N-mm T= F * (d/2) F= T/ (d/2) F= 20033/32 F= N Where F is the Tangential load d is the pitch circle diameter of the gear Module (m) = 3.2 mm No of teeth (z) =20 Face width (b) = 10mm editor@iaeme.com

4 T. Ramesh, K. Karthik, R. Ganesh 4.. FINITE ELEMENT ANALYSIS ANALYSIS OF SPUR GEAR Finite element modeling is described as the representation of the geometric model in terms of a finite number of element element and nodes. It is actually a numerical method employed for the solution of structures or a complex region defining a continuum. Solutions obtained by this method are rarely exact. However, errors in the approximate solution can be minimized by increasing the number of equations till the desired accuracy obtained. This is an alternative to analytical methods that are used for getting exact solution of analysis problems. The solution of general problem by finite. Element method always follows an orderly step step-by-step step process. For analysis in ANSYS The loading conditions are assumed to be static. The element choosen is solid 8 node185. Figure 1 Loads and boundary conditions of the gear. gear 5. RESULT AND DISCUSSION WITH OBTAINED FROM ANSYS From the static analysis using ansys the deflections and vonmise stress and strain values for plastic materials, such as like Nylon, polycarbonate, Acetal, polyesters, Polyphenyline, Liquid critical polymer are obtained as following below Figures and table. Figure 2 Stress ress distribution for Nylon gear Figure 3 Displacement pattern for Nylon spur gear Figure 4 Total mechanical strain for Nylon spur gear. asp 109 editor@iaeme.com

5 Design and Analysis of Plastics Gear for Heavy Duty Applications by FEA Method Plastic Materials Nylon Acetal Poly carbonate Polyester Polyphenyline Liquid Cristal polymer Graph: Various Materials Vs V Table 1 Analysis Result for Various Plastic Gear Materials Vonmise Stress (N/m2) Vonmise Stress Deflection (m) 0.891e e e e e Strain 0.791e e e e e e-3 Figure 5 Various materials vs Vonmise stress 6. CONCLUSIONS The minimum stress values are obtained for Nylon spur gear by comparing with these materials. According to the study, analysis, results and Graphs we recommend that the best plastic material is Nylon and Nylon gears are suitable for the future work, which is Geometric modification or selective re-inforceme ent and Geometric curve improve for strength improvement under AGMA. Now Plastic gear model was created of CATIA V5 and then it was export from CATIA V5 to ANSYS 11. In future gear set has been modeled in ANSYS Classic using APDL. It will be compared with experimental resultss in future. Future applications may take them between 5 to 10 hp in the near-term and up to 30 hp in the longterm. REFERENCES [1] Toshiki Hirogaki, Eiichi Aoyama, Tsutao Katayama, Shinya Iwasaki,Yoshinori Yagura, Kazuya Sugimura, Design systems for gear elements made of cotton fiber reinforced plastics, Composite Structures 66, (2004),PP [2] V.Siva Prasad,Syed Altaf Hussain, V.Pandurangadu, K.Palanikumar Modeling and Analysis of spur Gear for Sugarcane Juice Machine under Static Load Condition By Using FEA, International Journal of Modern Engineering Research (IJMER), issue.4,july-aug (2012), PP [3] Gun-Hee Kim, Jeong-Won Lee, and Tae-Il Seo, Durability haracteristics Analysis of Plastic Worm Wheel with Glass Fiber Reinforced Polyamide, Published: 10 May(2013), PP editor@iaeme..com

6 T. Ramesh, K. Karthik, R. Ganesh [4] Zan Smith, Andy Ulrich, Exploiting the Potential of Plastic Gears, Published : December (2012),PP [5] Choong Hyun Kim, Durability improvement method for plastic spur gears, Tribology International, 39 (2006), PP [6] Faruk Mendi, Hilal Can, Mustafa Kemal Ku lekc, Fatigue properties of polypropylene involute rack gear reinforced with metallic springs, Materials and Design, 27 (2006), PP [7] S. Senthilvelan, R. Gnanamoorthy, Influence of reinforcement on composite gear metrology, Mechanism and Machine Theory, 43 (2008), PP [8] Sebastian Fraulob, Jens Schirmer, Stefan Richter, Thomas Nagel Meshing Behaviour of Miniaturised Plastic Gear Pairs For Power Transmission Using Fem, 16, (2011),PP [9] Hu seyin Imrek, Performance improvement method for Nylon 6 spur gears Tribology International, 42 (2009), PP [10] Mrs.Shinde S.P., Mr. Nikam A.A., Mr. Mulla T.S, Static Analysis of Spur Gear Using Finite Element Analysis IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE), ISSN: , PP [11] Kenichi Terashima, Naohisa Tsukamoto, Jiasun Shi Development of Plastic Gears for Power Transmission: Power Transmission Mechanism of Plastic Gears, Japan Society of Mechanical Engineers (JSME), Vol. 27, No.231 (1984), PP [12] Kenichi Terashima, Naohisa Tsukamoto, Noriteru Nishida, Jiasun Shi, Development of Plastic Gear for Power Transmission: Abnormal Wear on the Tooth Root and Tooth Fracture near Pitch Point, Japan Society of Mechanical Engineers (JSME), Vol. 29, No.251 (1986), PP [13] HAO Yishu, Zhu Xinxing, Zhang Baogang, Thermal performance research of plastic helical gear and steel worm transmission, International Conference on Mechanic Automation and Control Engineering (MACE), (2010), PP [14] Pinaknath Dewanji, Design and Analysis of Spur Gear. International Journal of Mechanical Engineering and Technology, 7(5), 2016, pp [15] S. P. Chaphalkar and Subhash Khetre, Design and Mod el Analysis of Rear Axle with Two Ends Spur Geared Using FEA. International Journal of Mechanical Engineering and Technology, 7(6), 2016, pp [16] Vicky Lad and Dr. L. P. Singh, Design Modelling and Analysis of Helical Gear Using Catia, ANSYS and AGMA Parameters. International Journal of Mechanical Engineering and Technology, 7(4), 2016, pp editor@iaeme.com