A Study on the Effect of Variation Loads with Different Materials on the Spiral Bevel Gears

Abstract

Spiral bevel gear is typically adopted in high-speed mechanism components that transmit power and rotational motions amid dual intersecting shafts have (right angle axes). Therefore, because of the change in counterbalance, they may have slightly varies dynamic behaviour and gear mesh characteristics. Furthermore, the friction and lubrication effects may moreover play a significant character in its dynamic performances. The effect of variation loads with different materials on the spiral bevel gears have been analyzed and studied in this paper.

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A STUDY ON THE EFFECT OF VARIATION LOADS WITH DIFFERENT
MATERIALS ON THE SPIRAL BEVEL GEARS
JENAN MOHAMMED NAJE
Middle Technical University, Baghdad, Iraq
ABSTRACT
Spiral bevel gear is typically adopted in high-speed mechanism components that transmit power and rotational
motions amid dual intersecting shafts have (right angle axes). Therefore, because of the change in counterbalance, they
may have slightly varies dynamic behaviour and gear mesh characteristics. Furthermore, the friction and lubrication
effects may moreover play a significant character in its dynamic performances. The effect of variation loads with different
materials on the spiral bevel gears have been analyzed and studied in this paper.
KEYWORDS: Spiral Bevel Gear, Loads Effect, Loads Analyses & Material Durability
Received: Dec 16, 2018; Accepted: Jan 06, 2019; Published: Feb 02, 2019; Paper Id.: IJMPERDAPR20193
INTRODUCTION
Spiral Bevel Gears are commonly employed as a consequence of their suitability to transfer power
between nonparallel shafts at any speed or angle. It has curved and slope gear teeth concerning the pitch cone
surface [1].There are many indications that researchers have used in their laboratory experiments to study and
analyze gears [2, 3, 4]. Through comparison between Spiral bevel gears and straight bevel gears (zerol), have
supplementary overlapping tooth action, that generates a smoother gear mesh. This smooth power transmission for
the gear teeth lessens vibration and noise that raise exponentially at upper velocities[5, 6]. Consequently, the spiral
bevel gear ability for variation in the mechanical load direction, coupled with their capability in vibration and noise
decrease, create them a major applicant for usage in industry, advanced machine tools, vehicles and airplanes.
Many effective models have been proposed with the evolution and innovation of CFD technologies to calculate
and construct the bevel gear[7, 8]. A special-resolution finite element-established, gear tooth contact analysis tool
[9, 10]can be employed to accomplish 3D quasi-static loaded tooth contact investigation. The effectual gear mesh
depiction is adopted in the dynamic analysis and can be produced from the projected load distributions within the
tooth contact surface areas. Tsai and Hsu[11] estimated that, used a cup-shape grinder or milling cutter for
industrial the spiral bevel gear arrangements. They have resulting meshing restraint equation of bevel gear
arrangements having point contact characteristics. Also they arrange it to be a novel method for industrial spiral
bevel gears and the main characteristic is that the spiral bevel gears have single axis motion and which can be
controlled through the cutting process. R. Yakut et al. [12] examined the load capacity of PC/ABS spur gears and
investigated the gear damage. The usability of PC/ABS composite plastic material as spur gear has been as well
examined. The result shows that PC/ABS materials usage has a benefit in numerous manufacturing areas for the
reason that such materials are robust in contradiction of air, flame, ultraviolet lights and holding lower moister than
PA66 GFR 30materials.Litvin et al.[13] developed the local synthesis algorithm for design, industrial, stress
investigation of spiral bevel gears. Their experimental work results were expected by decreasing noise levels,
Original Article
International Journal of Mechanical and Production
Engineering Research and Development (IJMPERD)
ISSN(P): 2249-6890; ISSN(E): 2249-8001
Vol. 9, Issue 2, Apr 2018, 21-38
© TJPRC Pvt. Ltd.

22 Jenan Mohammed Naje
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minus vibration and improved toughness. The enhanced spiral bevel gear was obtainable through improving the bearing
contact as well as in the case of a parabolic function of transmission errors caused in the rising endurance limit of the gear
drives. Pio et al. [14]investigated a novel technique for kinematic and power flow investigation of the bevel epicyclical
gear train having gyroscopic difficulty. A new formula was assumed and substituted spur gear trains with bevel gears and
the Willis equation are additional improved with new power ratio expressions and the equation was validated with bevel
gears.
The finite element (FE) program for tooth contact analysis is used for gears modelling and analysis. As a result, an
exact information of the gear geometry is required. For the purpose of the complex bevel gear geometry, industrialized
simulations can beutilized in this subject[15].
In this manuscript Replacements of different composite materials of the gear under the different loading condition
and also the model analysis have performed with the intention of determining the stress, strain, total deformation, Fatigue
and expected durability under different loads for each material.
APPLIED MATERIALS
Structural Steel and Aluminium Alloy materials having an application in high power transmission system like a
gearbox used in automobile industries. For this purpose 3-D model of the helical gear pair with particular transmission
ratio, and comparing it with aluminum. It was made in SOLIDWORKS software and the ANSYS 19.0 fem based analysis
software was used as the analysis tool to carry out the static structural analysis in order to determine the behavior of both
materials (aluminum and steel).
Parametric Solid Modeling of Helical Gear
According to, the surface of the force acting, the direction and magnitude changes, Spiral bevel gear teeth has
convex and concave sides. They differ depending upon which is the driver and which is the driven. Figure 1 shows the
profile locations of right-hand and left-hand spiral teeth. In the case of the driving gear is convex, the driven gear profile
should be concave [16].
Figure 1: Convex and Concave Surfaces of a Spiral Bevel Gear
Torque used in a spiral bevel gear mesh stirs up tangential (circumferential), axil(thrust) and radial and separating
loads on the gear teeth. [17]Namely, these loads are presumed to be applied point loads at the middle-point of the face
width of the gear tooth. Separating and radial loads are reliant on the rotation direction and spiral hand along with pressure
angle, spiral angle and pitch angle[18]. Figure 2 depicts the forces influence on the bevel gear. In order to start analysis, the

A Study on the Effect of Variation Loads with Different Materials on the Spiral Bevel Gears
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initial step for investigating
a bevel gear is to
After selecting the suitable design of spiral bevel gear, the model is built as shown in
COMPUTER SOFTWARE
SOLIDWORKS and ANSYS 19.0
of advantages and dis-
advantages, and make a comparison with the experimental results.
Figure
Appling Mesh Type for the Model
In this part,
the model is cut into several small pieces to be analyzed for the identification of the stresses obtained
conical gear and as in the image
below, the
below show the analytic process.
A Study on the Effect of Variation Loads with Different Materials on the Spiral Bevel Gears
SCOPUS Indexed Journal
a bevel gear is to
regulate the forces on the gear tooth midpoint.
Figure 2: Force Analysis
After selecting the suitable design of spiral bevel gear, the model is built as shown in
SOLIDWORKS and ANSYS 19.0
have used to design (Figure
3), analyze the results to give primarily indication
advantages, and make a comparison with the experimental results.
Figure
3: Ansys Image of the Built Spiral Bevel Gear
the model is cut into several small pieces to be analyzed for the identification of the stresses obtained
below, the
me
sh value is acceptable according to Skewness value
23
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After selecting the suitable design of spiral bevel gear, the model is built as shown in
computer software section.
3), analyze the results to give primarily indication
the model is cut into several small pieces to be analyzed for the identification of the stresses obtained
sh value is acceptable according to Skewness value
that is near to 0. Figures

24
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Figure 4: Creating
New Material
Ansys-
Workbench
The consequential gear mesh
limitations
friction force path and friction
constant
such as the gear teeth mesh through
out
uniform in the case of
the dynamic analysis is completed
In this model, the force
attached to
shaft from the two sides of the
spiral bevel gear
is di
splayed and the variable is (100,200,300, 400 and
ANSYS ANALYSIS IN STATIC STRUCTURAL
Aluminum Alloy
For 100 N.mm Load, Model >
S
Figure 6:
Model > Static Structural > Solution >
Table 1: Details of
Model > Static Structural > Solution > Directional Deformation
Time [s]
1.
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New Material
in Figure 5: Mishing
Modele
Workbench
limitations
involve the operative mesh point, line-
of action, mesh stiffness,
constant
. All that limitations
are expected to differ with the variation in the contact regions
out
the engagement sector. The time-variation
performances
the dynamic analysis is completed
with a constant
insignificant gear rotating velocity
attached to
inclined teeth will be calculated as the
mechanism
spiral bevel gear
. This will be expressed in the ansys
package
splayed and the variable is (100,200,300, 400 and
500) N/m.
ANSYS ANALYSIS IN STATIC STRUCTURAL
AND SOLUTIONS
S
tatic Structural >Total Deformation is
as illustrated in
Model > Static Structural > Solution >
Full
Deformation
Model > Static Structural > Solution > Directional Deformation
Minimum [mm] Maximum [mm]
Average [mm]
0. 9.9568e-003 6.7697e-
003
Jenan Mohammed Naje
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Modele
Structure
of action, mesh stiffness,
residual
are expected to differ with the variation in the contact regions
performances
of mesh parameters are
insignificant gear rotating velocity
.
mechanism
will be connected by the
package
as fixed rotation. The torque
as illustrated in
Figure 6 and Table 1.
Deformation
Model > Static Structural > Solution > Directional Deformation
Average [mm]
003

A Study on the Effect of Variation Loads with Different Materials on the Spiral Bevel Gears
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For Model >Static S
tructural >
Figure 7:
Model > Static Structural > Solution >
Table 2: Details of
Model > Static Structural > Solution > Resultant Elastic Strain
Time [s]
Minimum
1.
5.0049e
For
Model > Static Structural > Solution >
Figure 8:
Model > Static Structural > Solution >
Table 3:
Details of
Time [s]
Minimum [MPa]
1.
A Study on the Effect of Variation Loads with Different Materials on the Spiral Bevel Gears
SCOPUS Indexed Journal
tructural >
Resultant Elastic, the results are in Figure 7 and
Table
Model > Static Structural > Solution >
Resultant
Elastic Strain
Model > Static Structural > Solution > Resultant Elastic Strain
Minimum
[mm/mm] Maximum [mm/mm]
Average [mm/mm]
5.0049e
-008 3.1615e-003
1.2843e
Model > Static Structural > Solution >
Resultant Stress, the results are in Figure
8 and
Model > Static Structural > Solution >
Resultant
Stress
Details of
Model > Static Structural > Solution >
Resultant
Minimum [MPa]
Maximum [MPa]
Average [MPa]
1.5279e-003 199.54 8.9725
25
editor@tjprc.org
Table
2.
Elastic Strain
Model > Static Structural > Solution > Resultant Elastic Strain
Average [mm/mm]
1.2843e
-004
8 and
Table 3.
Stress
Resultant
Stress
Average [MPa]

26
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For
Model > Static Structural > Solution > Fatigue Tool > Damage
Figure 9:
Model
Table 4: Details of
Model > Static Structural > Solution > Fatigue Tool > Damage
Time [s]
For 500 N.mm Load,
Model > Static
Table 5.
Figure 10:
Model > Static Structural > Solution >
Table 5: Details of
Model (F4) > Static Structural (F5) > Solution (F6) > Directional Deformation
Time [s]
1.
Impact Factor (JCC): 7.6197
SCOPUS Indexed Journal
Model > Static Structural > Solution > Fatigue Tool > Damage
,
the results are in
Model
> Static Structural
> Solution > Fatigue Tool > Damage
Model > Static Structural > Solution > Fatigue Tool > Damage
Time [s]
Minimum Maximum Average
1. 10. 21815 10.061
Model > Static
Structural > Solution >Total Deformation
is
Model > Static Structural > Solution >
Full
Deformation
Model (F4) > Static Structural (F5) > Solution (F6) > Directional Deformation
Minimum [mm] Maximum [mm]
Average [mm]
0. 4.9784e-002 3.3849e-
002
Jenan Mohammed Naje
NAAS Rating: 3.11
the results are in
Figure 9 and Table 4.
> Solution > Fatigue Tool > Damage
Model > Static Structural > Solution > Fatigue Tool > Damage
is
as shown in Figure 10 and
Deformation
Model (F4) > Static Structural (F5) > Solution (F6) > Directional Deformation
Average [mm]
002

A Study on the Effect of Variation Loads with Different Materials on the Spiral Bevel Gears
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For
Model > Static Structural > Solution >
Figure 11:
Model > Static Structural > Solution >
Table 6: Details of
Model > Static Structural > Solution > Resultant Elastic Strain
Time [s]
Minimum [mm/mm]
1.
2.5025e
For
Model > Static Structural > Solution >
Figure 12:
Model > Static Structural > Solution >
Table 7:
Details of
Time [s]
Minimum [MPa]
1.
A Study on the Effect of Variation Loads with Different Materials on the Spiral Bevel Gears
SCOPUS Indexed Journal
Model > Static Structural > Solution >
Resultant Elastic Strain,
the results are in
Model > Static Structural > Solution >
Resultant
Elastic Strain
Model > Static Structural > Solution > Resultant Elastic Strain
Minimum [mm/mm]
Maximum [mm/mm]
Average [mm/mm]
2.5025e
-007 1.5808e-002
6.4216e
Model > Static Structural > Solution >
Resultant Stress, the results are in
Figure
Model > Static Structural > Solution >
Resultant
Stress
Details of
Model > Static Structural > Solution > Resultant Stress
Minimum [MPa]
Maximum [MPa]
Average [MPa]
7.6396e-003 997.69 44.863
27
editor@tjprc.org
the results are in
Figure 11 and Table 6.
Elastic Strain
Model > Static Structural > Solution > Resultant Elastic Strain
Average [mm/mm]
6.4216e
-004
Figure
12 and Table 7.
Stress
Model > Static Structural > Solution > Resultant Stress
Average [MPa]

28
Impact Factor (JCC): 7.6197
For
Model > Static Structural > Solution
Model > Static Structural > Solution
Table 8: Details of
Model > Static
Time [s]
1.
The output of Constant Amplitude Load Fully Reversed in the case of Model > Static Structural > Solution >
Fatigue Tool is shown in Figure 14.
Figure
> Solution > Fatigue Tool > Results.
F
igure
Model > Static Structural > Solution > Fatigue Tool
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Model > Static Structural > Solution
> Fatigue Tool> Damage,
the results are in
Figure 13
Model > Static Structural > Solution
> Fatigue Tool> Damage
Model > Static
Structural > Solution > Fatigue Tool> Damage
Time [s]
Minimum Maximum Average
1.
10. 1.e+032 1.5852e+029
The output of Constant Amplitude Load Fully Reversed in the case of Model > Static Structural > Solution >
Figure
15 shows Mean stress correction theory in
the case of Model > Static Structural
igure
14: Constant Amplitude Load Fully Reversed,
Model > Static Structural > Solution > Fatigue Tool
Jenan Mohammed Naje
NAAS Rating: 3.11
the results are in
Figure 13 and Table 8.
Structural > Solution > Fatigue Tool> Damage
The output of Constant Amplitude Load Fully Reversed in the case of Model > Static Structural > Solution >
the case of Model > Static Structural

A Study on the Effect of Variation Loads with Different Materials on the Spiral Bevel Gears
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Figure
Model > Static Structural > Solution > Fatigue Tool > Results
Structural Steel
For 100 N.mm Load, Model >
Static Structural >
Figure
1
Table 9:
Details of
Time [s]
1.
A Study on the Effect of Variation Loads with Different Materials on the Spiral Bevel Gears
SCOPUS Indexed Journal
Figure
15: Mean Stress Correction Theory,
Model > Static Structural > Solution > Fatigue Tool > Results
Static Structural >
Total Deformation as illustrated in
Figure
1
6: Model >Static Structural >Total Deformation
Details of
Model >Static Structural >
Total Deformation
Minimum [m] Maximum [m]
Average [m]
0. 3.4813e-006 2.3528e-
006
29
editor@tjprc.org
Model > Static Structural > Solution > Fatigue Tool > Results
Figure
16 and Table 9.
Total Deformation
Average [m]
006

30
Impact Factor (JCC): 7.6197
For
Model > Static Structural > Solution >
Figure 17:
Model > Static Structural > Solution >
Table 10: Details of
Model > Static Structural > Solution > Resultant Elastic Strain
Time [s]
Minimum [m/m]
1.
For
Model > Static Structural > Solution >
Figure 18:
Model > Static Structural > Solution >
Table 11:
Details of
Time [s]
1.
Impact Factor (JCC): 7.6197
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Model > Static Structural > Solution >
Resultant Elastic Strain, the results are in
Figure
Model > Static Structural > Solution >
Resultant
Elastic Strain
Model > Static Structural > Solution > Resultant Elastic Strain
Minimum [m/m]
Maximum [m/m]
Average [m/m]
1.8758e-008 1.1142e-003 4.5543e-
005
Model > Static Structural > Solution >
Resultant Stress, the results are in Figure
18 and
Model > Static Structural > Solution >
Resultant
Stress
Details of
Model > Static Structural > Solution > Resultant
Minimum [Pa] Maximum [Pa]
Average [Pa]
1723.7 1.9763e+008 8.9619e+006
Jenan Mohammed Naje
NAAS Rating: 3.11
Figure
17 and Table 10.
Elastic Strain
Model > Static Structural > Solution > Resultant Elastic Strain
Average [m/m]
005
18 and
Table 11.
Stress
Model > Static Structural > Solution > Resultant
Stress
Average [Pa]

A Study on the Effect of Variation Loads with Different Materials on the Spiral Bevel Gears
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For
Model > Static Structural > Solution > Fatigue Tool> Damage
Figure 19:
Model > Static Structural > Solution >
Table 12:
Details of
Time [s]
For 500 N.mm Load, Model >
Static Structural >
Figure
20
Table 13:
Details of
Time [s]
1.
A Study on the Effect of Variation Loads with Different Materials on the Spiral Bevel Gears
SCOPUS Indexed Journal
Model > Static Structural > Solution > Fatigue Tool> Damage
,
the results are in
Model > Static Structural > Solution >
Fatigue Tool> Damage
Details of
Model > Static Structural > Solution > Fatigue Tool> Damage
Time [s]
Minimum Maximum Average
1. 1000. 37341 1000.3
Static Structural >
Total Deformation as illustrated in
Figure
20
: Model >Static Structural >Total Deformation
Details of
Model >Static Structural >
Total Deformation
Time [s]
Minimum [m] Maximum [m] Average [m]
0. 1.7406e-005 1.1764e-005
31
editor@tjprc.org
the results are in
Figure 19 and Table 12.
Fatigue Tool> Damage
Model > Static Structural > Solution > Fatigue Tool> Damage
Figure
20 and Table 13.
Total Deformation

32
Impact Factor (JCC): 7.6197
For
Model > Static Structural > Solution
Figure 21:
Model > Static Structural > Solution >
Table 14: Details of
Model > Static Structural > Solution > Resultant Elastic Strain
Time [s]
Minimum [m/m]
1.
For
Model > Static Structural > Solution >
Figure 22:
Model > Static Structural > Solution >
Table 15:
Details of
Time [s]
1.
Impact Factor (JCC): 7.6197
SCOPUS Indexed Journal
Model > Static Structural > Solution
>Resultant Elastic Strain,
the results are in
Model > Static Structural > Solution >
Resultant
Elastic Strain
Model > Static Structural > Solution > Resultant Elastic Strain
Minimum [m/m]
Maximum [m/m]
Average [m/m]
9.379e-008 5.5712e-003 2.2772e-
004
Model > Static Structural > Solution >
Resultant Stress,
the results are depicted in
Model > Static Structural > Solution >
Resultant
Stress
Details of
Model > Static Structural > Solution > Resultant Stress
Minimum [Pa] Maximum [Pa]
Average [Pa]
8618.5 9.8815e+008 4.4809e+007
Jenan Mohammed Naje
NAAS Rating: 3.11
the results are in
Figure 21 and Table 14.
Elastic Strain
Model > Static Structural > Solution > Resultant Elastic Strain
Average [m/m]
004
the results are depicted in
Figure 22 and Table 15.
Stress
Model > Static Structural > Solution > Resultant Stress
Average [Pa]

A Study on the Effect of Variation Loads with Different Materials on the Spiral Bevel Gears
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For
Model > Static Structural > Solution > Fatigue Tool> Damage
Table 16.
Figure 23:
Model > Static Structural > Solution > Fatigue Tool> Damage
Table 16:
Details of
Time [s]
The output of Constant Amplitude Load Fully Reversed in the case of Model > Static Structural > Solution >
Fatigue Tool is shown in Figure 24.
Figure
> Solution > Fatigue Tool > Results.
Figure 24:
Constant Amplitude Load Fully Reversed, Model > Static Structural > Solution > Fatigue Tool
A Study on the Effect of Variation Loads with Different Materials on the Spiral Bevel Gears
SCOPUS Indexed Journal
Model > Static Structural > Solution > Fatigue Tool> Damage
,
the results are depicted in
Model > Static Structural > Solution > Fatigue Tool> Damage
Details of
Model > Static Structural > Solution > Fatigue Tool> Damage
Time [s]
Minimum Maximum Average
1. 1000. 4.0753e+006 3277.5
The output of Constant Amplitude Load Fully Reversed in the case of Model > Static Structural > Solution >
Figure
25 shows Mean stress correction theory in
the case of Model > Static Structural
Constant Amplitude Load Fully Reversed, Model > Static Structural > Solution > Fatigue Tool
33
editor@tjprc.org
the results are depicted in
Figure 23 and
Model > Static Structural > Solution > Fatigue Tool> Damage
Model > Static Structural > Solution > Fatigue Tool> Damage
The output of Constant Amplitude Load Fully Reversed in the case of Model > Static Structural > Solution >
the case of Model > Static Structural
Constant Amplitude Load Fully Reversed, Model > Static Structural > Solution > Fatigue Tool

34
Impact Factor (JCC): 7.6197
Figure
Model > Static Structural > Solution > Fatigue Tool > Results
RESULTS AND DISCUSSION
Results are classified to
realize
with respect to load as shown in
Figure
and Aluminum Alloy with
respect to load
organize the
Structural Steel and Aluminum Alloy
Structural Steel is appropriate
to be used in
mechanical features. Aluminium Alloy
anti-corrosion.
Figure 26:
Total
Figure
27
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Figure
25: Mean Stress Correction Theory,
Model > Static Structural > Solution > Fatigue Tool > Results
realize
the total deformation difference between the
Structural Steel and Aluminum Alloy
Figure
26 and Figure 29. Also, results are shown for
Shear Stress between
respect to load
as depicted in Figures 27, 28, 30, and 31 to
calculate the durability and to
Structural Steel and Aluminum Alloy
uses in Spiral Bevel Gears.
Accordingly, based on above figures, the
to be used in
Spiral Bevel Gears as it
has corrosion and erosion resistance
is
suitable to be used for light weight purposes, having good thermal conductivity,
Total
Deformation between Structural Steel and
Load
27
: Shear Stress between Structural Steel and Load
Jenan Mohammed Naje
NAAS Rating: 3.11
Model > Static Structural > Solution > Fatigue Tool > Results
Structural Steel and Aluminum Alloy
Shear Stress between
Structural Steel
calculate the durability and to
Accordingly, based on above figures, the
has corrosion and erosion resistance
with high
suitable to be used for light weight purposes, having good thermal conductivity,
Load

A Study on the Effect of Variation Loads with Different Materials on the Spiral Bevel Gears 35
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Figure 28: Shear Elastic Strain between Structural Steel and Load
Figure 29: Total Deformation between Aluminum Alloy and Load
Figure 30: Shear Stress between Aluminum Alloy and Load
Figure 31: Shear Elastic Strain between Aluminum Alloy and Load

36 Jenan Mohammed Naje
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CONCLUSIONS
Theoretical study has been carried out to estimate the performance of Spiral Bevel Gears, and to choose suitable
metal according to the working procedure.
The Structural Steel is proper to be used in Spiral Bevel Gears since it has corrosion and erosion resistant, with
high mechanical properties (hardness, bending and impact resistance).
Aluminium Alloy suitable to be used for light weight purposes, having good thermal conductivity, anti-corrosion.
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