Optimum Gear Tooth Geometry for Minimum Fillet Stress Using BEM and Experimental Verification With Photoelasticity

Abstract

This paper introduces the concept of nondimensional gear teeth to be used in gear stress minimization problems. The proposed method of modeling reduces the computational time significantly when compared to other existing methods by essentially reducing the total number of design variables. Instead of modeling the loaded gear tooth and running BEA to calculate the maximum root stress at every iterative step of the optimization procedure, the stress is calculated by interpolation of tabulated values, which were calculated previously by applying the BEM on nondimensional models corresponding to different combinations of the design parameters. The complex algorithm is used for the optimization and the root stresses of the optimum gears are compared with the stresses of the standard gears for the same transmitted torque. Reduction in stress up to 36.5% can be achieved in this way. This reduction in stress has been confirmed experimentally with two-dimensional photoelasticity.

Modelling Dependencies and Couplings in the Design Space of Meshing Gear Sets

“…Let us first consider a formal optimisation for bending stress, i.e. as per [13]. From the stress tables in that work we obtain the optimum design shown in Table 3.…”

“…Table 3. Embodiment #1 as per [13] . By applying unitary loads at the HPSTC, the maximum nondimensional tensile stress can be calculated for each gear by means of FEA, as seen in Fig.…”

A Mathematical Model for Parametric Tooth Profile of Spur Gears

“…Lin et al [26] used the combined mutation differential evolution algorithm to engage the involute tooth profile with full-depth displacement. Spitas et al [27] solved the problem of gear stress minimization by using the concept of dimensionless gear teeth. is method effectively reduced the number of design variables and calculation time [27].…”

“…Spitas et al [27] solved the problem of gear stress minimization by using the concept of dimensionless gear teeth. is method effectively reduced the number of design variables and calculation time [27].…”

Experimental Investigation of Load Sharing in Multiple Gear Tooth Contact Using the Stress‐Optical Method of Caustics

“…contact points, critical sections, etc. Photoelasticity has been widely used for the experimental stress analysis of gears, particularly, because it offers a convenient way of assessing the maximum stress at the tooth root fillet (Lingaiah and Ramachandra [8], Deuschle et al [9], Wang [10], Novikov et al [11], Spitas et al [12], Spitas and Spitas [13]). Although popular, photoelasticity is practically impossible to use in high stress concentration regions such as contact points and crack tips because of the very high density of the isochromatic fringes near the point of stress singularity.…”