Swinburne University of Technology (Sarawak

Campus)

Faculty of Engineering, Computing and Science

MEE40008 Final Year Research Project 1 (Mechanical)

Project Logbook

Author: Supervisor:
Ibrahim Hussaini (4241606) Dr. Soon Kok Heng

May 27, 2016

Project Logbook Ibrahim Khalil Hussaini (4241606)

Contents

1 Supervision meeting register 3

2 Week 1 6
2.1 Preliminary research . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1.1 Videos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1.2 Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.3 Websites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1.4 Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.5 Description of activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3 Week 2 16
3.1 Sketch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3 Description of activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4 Week 3 21
4.1 Modeling an equation driven involute spur gear in SolidWorks . . . . . . . . . . . . . . 21
4.1.1 Videos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2 Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.3 Description of activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5 Week 4 25
5.1 Simulations undertaken . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1.1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1.1.1 Module m = 8.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1.1.2 Module m = 12.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1.1.3 Module m = 17.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.1.1.4 Module m = 21.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1.1.5 Module m = 26.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.2 Description of activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6 Week 5 32
6.1 b module results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.2 Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.3 Description of activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

7 Week 6 34
7.1 Simulations undertaken . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.1.1 Pressure angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.1.1.1 Pressure angle = 14.5 . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.1.1.2 Pressure angle = 20 . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.1.1.3 Pressure angle = 25 . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.2 Description of activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

8 Week 7 38
8.1 b pressure angle results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.2 Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.3 Description of activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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Project Logbook Ibrahim Khalil Hussaini (4241606)

9 Week 8 40
9.1 Simulations undertaken . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.1.1 Number of teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.1.1.1 Number of teeth Np = 15 . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.1.1.2 Number of teeth Np = 17 . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.1.1.3 Number of teeth Np = 20 . . . . . . . . . . . . . . . . . . . . . . . . . 42
9.1.1.4 Number of teeth Np = 24 . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.1.1.5 Number of teeth Np = 30 . . . . . . . . . . . . . . . . . . . . . . . . . 44
9.2 Description of activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

10 Week 9 46
10.1 b number of teeth results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
10.2 Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
10.3 Description of activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

11 Week 10 48
11.1 Sketch 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11.2 Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11.3 Description of activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

12 Week 11 51
12.1 Recommended alternative model setup . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12.1.1 ANSYS Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12.1.2 SolidWorks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12.2 Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12.3 Description of activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

13 Week 12 54
13.1 Sketch 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
13.2 Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
13.3 Description of activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

14 Week 13 56
14.1 Hertzian contact stress model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
14.2 Videos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
14.3 Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
14.4 Websites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
14.5 Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

15 Relevant standards 84
15.1 Spur gear pressure angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
15.2 Actual sizes of gear teeth of various diametral pitches. . . . . . . . . . . . . . . . . . . 85
15.3 Recommended alternative model setup . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

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 Project Logbook
1 Supervision meeting register

Week Date Actions achieved Issues discussed Actions for next meeting
1 29/02/16 - Research more about the topic

1. Submission of topic form

2 07/03/16 - How does ANSYS and SolidWorks solve a spur gear

stress analysis problem?
1. Brief explanation about the topic
and initial areas of research

2. Discussed the importance of this re-

search project.

3 14/03/16

1. Discussion on AGMA/ISO findings
and FEA.
2. Decided to include module param-
eter in bending and contact stress
simulations
1. Decision to use only 1. ANSYS setup for spur gear simulation
standard module values
of 8.3, 12.7, 17.5, 21.9 2. Conduct b module simulations
and 26.3 mm.

Ibrahim Khalil Hussaini (4241606)

4 21/03/16 -

1. Load factor assumptions. 1. Plot and interpret the the results from the b
module simulations.

5 28/03/16

1. Research plan content 1. The flow of the research 1. Conduct b pressure angle simulations.
plan and problem state-
ment

2. Decision to use only

standard values of Lewis
form factor Y for spur
gears (i.e 14.5, 20 and 25
degrees).
 Project Logbook
6 04/04/16 -

1. Discussion of results and validity. 1. Plot and interpret the the results from the b
pressure angle simulations.

7 11/04/16

1. Decided to include number of teeth
parameter in bending and contact
stress simulations.
2. Discussed yielding effects.
1. Decision to use only 1. Conduct b number of teeth simulations
standard module values
of 15, 17, 20, 24 and 30
teeth.

8 18/04/16 -

1. Discussion of results and validity 1. Plot and interpret the the results from the b
number of teeth simulations.

9 25/04/16 -

1. Discussion of results and validity. 1. Derive expression for the hertzian contact stress
of a cylinder with respect to parameters such as
module, pressure angle and number of teeth.

10 02/05/16

Ibrahim Khalil Hussaini (4241606)

1. Discussion of results and validity
1. Why am i using setup 1. Conduct simulations on the recommended alter-
conditions such as fric- native model setup
tionless support, fixed
support, and applied
moment?

11 09/05/16

1. Discussion of results and validity 1. Why the results of the 1. Comparison of the results of the recommended
recommended alterna- alternative model setup to the Lewis setup
tive model setup are model.
different to the Lewis
setup model.
 Project Logbook
12 16/05/16

1. Hertzian contact stress model 1. Why is the simulation 1. Conduct simulations on hertzian contact stress
to be done on quarter distributions on two cylinders of the same diam-
2. Discussion of results and validity cylinders? eter.

13 23/05/16

1. Compilation of works 1. Non convergence prob- 1. Plot and interpret the the results from the
lem hertzian contact stress model simulations.

2. Submit progress report

3. Submit workbook

4. Submit poster

Ibrahim Khalil Hussaini (4241606)

Project Logbook Ibrahim Khalil Hussaini (4241606)

2 Week 1
2.1 Preliminary research
2.1.1 Videos

Figure 1: url: https://www.youtube.com/watch?v=B8Afi3bP1Xo

This Video explains how one can model a spur gear with true involute profile teeth in ANSYS. It
involves numerical calculation of coordinates, drawing an involute curve, drawing circles, completing
the tooth profile, replicating the tooth profile, replicating the tooth 19 times, trimming away unwanted
segments, and finally, an extrude to create a 3D solid.

Figure 2: url: : url:https://www.youtube.com/watch?v=Q_UqIM9ZoxQ

In this video, a simulation is conducted for a pair of meshing spur gears introduced in section
1.1.1.The goal is to asses the maximum stress during transmission of a torque of 15000 lb-in. An
engineering judgement reaveals that the maximum stress occurs at either contact point.

Page 6
Ibrahim Khalil Hussaini (4241606)

Page 7
Chapter 2 Sketching Section 2.5 Spur Gears 16
Section 2.5
Spur Gears
Problem Description
To satisfy the fundamental law
of gearing, the gear proles
are cut to an involute curve.
Documents
Project Logbook

2.1.2
Ibrahim Khalil Hussaini (4241606)

Page 8
Chapter 2 Sketching Section 2.5 Spur Gears 17
[1] The driving [8] Line of action (common
gear rotates normal of contacting gears).
clockwise. The pressure angle is 20o.
[2] The driven
gear rotates
counter- [4] Pitch circle
clockwise. of the driving
[6] Contact
point (pitch
[3] Pitch circle point).
rp = 2.5 in. [7] Common
[5] Line of tangent of the
centers. pitch circles.
[9] Addendum
ra = 2.75 in.
[12] The llet
has a radius of
0.1 in.
[10]
Dedendum
rd = 2.2 in. [11] The shaft has a
radius of 1.25 in.
Project Logbook
Ibrahim Khalil Hussaini (4241606)

Page 9
Chapter 2 Sketching Section 2.5 Spur Gears 18
Techniques/Concepts
Draw>Construction Point
Draw>Spline
Modify>Replicate
Constraints>Perpendicular
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Ibrahim Khalil Hussaini (4241606)

Page 10
Chapter 3 2D Simulations Section 3.4 Spur Gears 15
Section 3.4
Spur Gears
Problem Description [1] W are
concerned with the
contact stress here.
[2] And the bending
stress here.
Project Logbook
Ibrahim Khalil Hussaini (4241606)

Page 11
Chapter 3 2D Simulations Section 3.4 Spur Gears 16
Techniques/Concepts
Copy bodies (Translate)
Contacts
Frictionless
Symmetric (Contact/Target)
Adjust to Touch
Loads>Moment
True Scale
Project Logbook
Project Logbook Ibrahim Khalil Hussaini (4241606)

2.1.3 Websites

Finite Element Simulations with ANSYS Workbench 16 by Huei-Huang Lee, NCKU, Taiwan 04/05/2016, 11:47 PM

Books MATLAB2016 ANSYS16 ANSYS15 SWM2015 SWM2014 SWD2015 SWD2014

SWS2015 Taguchi4 TaguchiOpenCourse Dynamics

Finite Element Simulations with ANSYS Workbench 16

by Huei-Huang Lee, NCKU, Taiwan

Amazon.com Search--ANSYS
Amazon.com Search--Finite Element
Google Search--Finite Element Simulations with ANSYS Workbench

Download Lecture Slides

(PDF) Chapter 01. Introduction (Word) Chapter 01

(PDF) Chapter 02. Sketching (Word) Chapter 02
(PDF) Chapter 03. 2D Simulations (Word) Chapter 03
(PDF) Chapter 04. 3D Solid Modeling (Word) Chapter 04
(PDF) Chapter 05. 3D Simulations (Word) Chapter 05
(PDF) Chapter 06. Surface Models (Word) Chapter 06
(PDF) Chapter 07. Line Models (Word) Chapter 07
(PDF) Chapter 08. Optimization (Word) Chapter 08
(PDF) Chapter 09. Meshing (Word) Chapter 09
(PDF) Chapter 10. Buckling and Stress Stiffening (Word) Chapter 10
(PDF) Chapter 11. Modal Analyses (Word) Chapter 11
(PDF) Chapter 12. Transient Structural Simulations (Word) Chapter 12
(PDF) Chapter 13. Nonlinear Simulations (Word) Chapter 13
To order this book, please visit
(PDF) Chapter 14. Nonlinear Materials (Word) Chapter 14
SDC Publications or Amazon.com
(PDF) Chapter 15. Explicit Dynamics (Word) Chapter 15

View Tutorial Videos or Download Finished Project Files

1. The videos have a maximum resolution of 1920x1080 (HD).
2. To reduce file size, the project files were saved with Workbench GUI command /File/Archive...; i.e., they are in WBPZ compressed format. To
open a compressed project file, please use Workbench GUI command /File/Restore Archive...
3. The project files are to be used with ANSYS16 (or later); they are not to be used with ANSYS15 or earlier versions.
4. It is suggested that, whenever a project file is needed to start up an exercise, you use a project file provided here, rather than your own finished
project file, so that your numerical results would be more consistent with those in the textbook.

(Video 05:29) Section 02-1
(Video 05:16) Section 02-2
(Video 05:31) Section 02-4
(Video 06:46) Section 02-5
(Video 08:23) Section 02-6
(Video 07:05) Section 03-1
(Video 09:44) Section 03-2
(Video 05:45) Section 03-4
(Video 11:59) Section 03-5
(Video 03:50) Section 04-1
(Video 12:15) Section 04-2
W16x50 Beam (Finished Project File) Sec 02-1 (Animation) Sec 01-1
Triangular Plate (Finished Project File) Sec 02-2
M20x2.5 Threaded Bolt (Finished Project File) Sec 02-4
Spur Gears (Finished Project File) Sec 02-5
Microgripper (Finished Project File) Sec 02-6
Triangular Plate (Finished Project File) Sec 03-1 (Animation) Sec 03-1
Threaded Bolt-and-Nut (Finished Project File) Sec 03-2 (Animation) Sec 03-2
Spur Gears (Finished Project File) Sec 03-4 (Animation) Sec 03-4
Filleted Bar (Finished Project File) Sec 03-5 (Animation) Sec 03-5
Beam Bracket (Finished Project File) Sec 04-1
Cover of Pressure Cylinder (Finished Project File) Sec 04-2

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Finite Element Simulations with ANSYS Workbench 16 by Huei-Huang Lee, NCKU, Taiwan 04/05/2016, 11:47 PM
Project Logbook Ibrahim Khalil Hussaini (4241606)

(Video 06:39) Section 04-3 Lifting Fork (Finished Project File) Sec 04-3
(Video 06:33) Section 04-5 LCD Display Support (Finished Project File) Sec 04-5
(Finished Project File) Sec 04-6-2
(Video 04:12) Section 05-1 Beam Bracket (Finished Project File) Sec 05-1 (Animation) Sec 05-1
(Video 04:23) Section 05-2 Cover of Pressure Cylinder (Finished Project File) Sec 05-2 (Animation) Sec 05-2
(Video 03:20) Section 05-4 LCD Display Support (Finished Project File) Sec 05-4 (Animation) Sec 05-4
(Video 07:50) Section 06-1 Bellows Joints (Finished Project File) Sec 06-1 (Animation) Sec 06-1
(Video 05:29) Section 06-2 Beam Bracket (Finished Project File) Sec 06-2 (Animation) Sec 06-2
(Video 11:37) Section 06-3 Gearbox (Finished Project File) Sec 06-3 (Animation) Sec 06-3
(Video 08:00) Section 07-1 Flexible Gripper (Finished Project File) Sec 07-1 (Animation) Sec 07-1
(Video 11:56) Section 07-2 3D Truss (Finished Project File) Sec 07-2 (Animation) Sec 07-2
(Video 13:18) Section 07-3 Two-Story Building (Finished Project File) Sec 07-3 (Animation) Sec 07-3
(Video 07:51) Section 08-1 Flexible Gripper (Finished Project File) Sec 08-1 (Animation) Sec 08-1
(Video 05:51) Section 08-2 Triangular Plate (Finished Project File) Sec 08-2 (Animation) Sec 08-2
(Video 11:59) Section 09-1 Pneumatic Fingers (Finished Project File) Sec 09-1 (Animation) Sec 09-1
(Video 05:25) Section 09-2 Cover of Pressure Cylinder (Finished Project File) Sec 09-2
(Video 11:37) Section 09-3 Convergence of 3D Elements (Finished Project File) Sec 09-3 (Animation) Sec 09-3
(Video 07:58) Section 10-1 Stress Stiffening (Finished Project File) Sec 10-1 (Animation) Sec 10-1
(Video 02:19) Section 10-2 3D Truss (Finished Project File) Sec 10-2 (Animation) Sec 10-2
(Video 02:25) Section 10-3 Beam Bracket (Finished Project File) Sec 10-3 (Animation) Sec 10-3
(Video 02:19) Section 11-1 Gearbox (Finished Project File) Sec 11-1 (Animation) Sec 11-1
(Video 04:18) Section 11-2 Two-Story Building (Finished Project File) Sec 11-2 (Animation) Sec 11-2
(Video 05:45) Section 11-3 Compact Disk (Finished Project File) Sec 11-3 (Animation) Sec 11-3
(Video 03:59) Section 11-4 Guitar String (Finished Project File) Sec 11-4 (Animation) Sec 11-4
(Video 07:24) Section 12-2 Lift Fork (Finished Project File) Sec 12-2 (Animation) Sec 12-2
(Video 04:03) Section 12-3 Two-Story Building (Finished Project File) Sec 12-3
(Video 08:37) Section 12-4 Disk and Block (Finished Project File) Sec 12-4 (Animation) Sec 12-4
(Video 05:35) Section 12-5 Guitar String (Finished Project File) Sec 12-5 (Animation) Sec 12-5
(Video 09:47) Section 13-2 Translational Joint (Finished Project File) Sec 13-2 (Animation) Sec 13-2
(Video 11:33) Section 13-3 Microgripper (Finished Project File) Sec 13-3 (Animation) Sec 13-3
(Video 14:18) Section 13-4 Snap Lock (Finished Project File) Sec 13-4 (Animation) Sec 13-4
(Video 11:36) Section 14-2 Belleville Washer (Finished Project File) Sec 14-2 (Animation) Sec 14-2
(Video 14:17) Section 14-3 Planar Seal (Finished Project File) Sec 14-3 (Animation) Sec 14-3
(Testdata.xls) Test Data Sec 14-3
(Video 05:43) Section 15-2 High-Speed Impact (Finished Project File) Sec 15-2 (Animation) Sec 15-2
(Video 08:05) Section 15-3 Drop Test (Finished Project File) Sec 15-3 (Animation) Sec 15-3

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2.1.4 Questions
1. What is finite element analysis?
2. What is fiinite element method?
3. How do i draw a spur gear with different pressure angles, module and number of teeth?
4. How do i perform the simulations in ANSYS as well as SolidWorks?

2.1.5 Description of activities

Monday
1. Overview of Final Year Research Project 1 Activity.

Studying through the FYRP1 unit outlined as made available on the blackboard learning
system.
Understanding the demands and requirements of the research project in regards to the Re-
search plan, oral & poster presentation, Progress report and the process portfolio/Workbook
assessments.

2. Topics Analysis

Briefly researching about the list of topics made available for research and understanding
the requirements research to be conducted accordingly.
After the preliminary analysis of the listed topics, I finally decided to take up a title related
to machine design.

Tuesday
1. Topic Selection

On the first meeting with the unit convernor i.e Dr Saravana Thangavelu (FECS) I chose
the topic Modelling the Effect of Involute Spur Gear pressure angle on the Bending Stress.
I emailed my completed research project registration form to the unit convener.
I was assigned to Dr Soon Kok Heng as my research project supervisor and scheduled a
meeting with him after.

Wednesday
1. Final Year Research Project 1 First Lecture

The first lecture was conducted by the convernor, where further briefing regarding the
research project was provided.

2. First day of Meeting with Supervisor

Discussed further about the topic, setting agenda on the possible research areas, require-
ments and desired outcomes.

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Thursday
1. Researched related online resources on the effect of involute spur gear pressure angle on the
bending stress with the following list of titles.

Effect of pressure angle of spur gears on bending and contact stresses: a comparative study
using finite element software
Finite element modeling and bending stress analysis of non standard spur gear
Stress analysis of mating involute spur gear teeth
Stresses and deformations in involute spur gears by finite element method

2. Having read through these articles, I realized that many several authors regarding the finite
element modelling of spur gear teeth with respect to pressure angle have carried out extensive
research.

3. I requested topic change the title of the topic to modelling of an involute spur gear via finite
element method with my supervisor for a less researched areas, where I decided to also investigate
hertzian contanct stress as well as bending stress with respected to additional parameters such
as module pressure angle and number of teeth.

Friday
1. Modules 1 Activity

Completed in activity 2.1, i.e the student and supervisor expectation survey form regarding
the areas of study, contact/involvement and project.
Completed in activity 2.2, i.e the supervisor meeting agreement form.

Supervisor Name Date & Signature

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3 Week 2
3.1 Sketch 1

Ft Ft
s = = (1)
bym bY m
Accounts for the geometry of the gear tooth but does not consider stress concentrations.

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Project Logbook Ibrahim Khalil Hussaini (4241606)

Figure 3: Bending stresses in a spur gear tooth (comparison with a constant-stress parabola). Credit:
Robert C. Juvinall and Kurt M. Marshek - Fundamentals of Machine Component Design, 5th Edition.

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3.2 Questions
1. What is the difference between finite element analysis and finite element method?

2. How do i model gears with different parameters with easy and efficiency?

3. How do i model an equation driven involute spur gear?

4. Should i model the gears in ANSYS as opposed to exporting them from SolidWorks?

5. How does ANSYS solve a gear stress problem?

6. What is the difference between AGMA, ISO and the Lewis equation?

7. Why does this project need research?

3.3 Description of activities

Monday
1. Researched on the fundamentals of gear bending and contact stress

2. Researched about the fundamental gear parameters which are

Module
Pressure angle
Number of teeth

3. Researched on how the variation in pressure angle affects gear bending and contact stress

4. Researched on how the variation in module affects gear bending and contact stress

5. Researched on how the variation in number of teeth affects gear bending and contact stress

Tuesday
1. Meeting with supervisor for further discussions about the topic

Instructed to conduct research on bending and contact stress computational models.

To research about possible research gaps regarding my topic in other to identify the research
outcomes and objectives
Planning on of the research procedure by experimenting bending stress in FYRP 1, while
experimenting contact stress in FYRP 2.
Supervisor also emphasized to do adequate readings and research in other to understand
optimally the whole idea about the research topic.
Explained how to go about conducting the experiment in ANSYS with respect to model
setup and boundary conditions.

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Wednesday
1. Creating ghant chart for semester 1 and 2 after consultation and agreement of the structure with
my supervisor.

2. Going through the feedback assessment at module 1.3 while understanding how to feedbacks are
necessary during the research.

3. Research on how contact Stress calculation and bending stress calculation is play more significant
role in the design of gear after reading through:

International Journal of Engineering Research & Technology (IJERT) with title Stress
Analysis of Mating Involute Spur Gear Teeth.

Thursday
1. Studied the the paper Stress Analysis of Composite Spur Gear

Understood from the above paper that conducted research on the static stress characteristics
of an involute composite spur gear system including bending stresses and contact stresses
of gears in mesh and comparing it with the existing involute cast iron spur gear system.
The objective of the work was to replace the cast iron spur gear with carbon fibre epoxy
composite spur gear.
The paper concluded that the cast iron spur gear can be replaced by Carbon fiber re-
inforced epoxy (composite) spur gear due to its high strength, low weight and damping
characteristics.

Friday
1. Further literature reading on relevant gear parameter behaviors.

Studied the the paper Finite element modeling and bending stress analysis of non standard
spur gear
Understood from the above paper that conducted research on non standard that the as-
sessment of pressure angle modification on drive side leads to interesting conclusions.
It was observed that while the pressure angle modification affects the gear tooth geometry,
the modification study is itself limited by gear parameters.
It was observed that the pressure angle has insignificant influence on the induced stress
whereas the bending stress is considerably reduced by increasing the pressure angle.
I understood that with increasing pressure angle, gears can be operated with lesser number
2
of teeth compared to AGMA standards (Zmin = ) = 17.097 since, undercutting is
sin2 (20)
avoided.
It was observed that the shape of the tooth becomes more pointed or peaked and the tooth
flank becomes more curved.
I understood that the asymmetric tooth geometry allows for an increase in load carrying
capacity while reducing the weight and dimensions for gears.

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Supervisor Name Date & Signature

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4 Week 3
4.1 Modeling an equation driven involute spur gear in SolidWorks

Figure 4: Design input parameters

xt = D2@Sketch2 0.5 (cos(t) + t sin(t)) (2)

yt = D2@Sketch2 0.5 (sin(t) t cos(t)) (3)

xt = D2@Sketch2 0.5 (cos(t 2 D4@Sketch2 pi/180)

t sin(t 2 D4@Sketch2 pi/180)) (4)

yt = D2@Sketch2 0.5 (sin(t 2 D4@Sketch2 pi/180)

+ t cos(t 2 D4@Sketch2 pi/180)) (5)

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4.1.1 Videos

Figure 5: url: https://www.youtube.com/watch?v=uj7BnldaOSc

The method given in this video works when diameter of base circle is bigger than that of the
dedendum circle. When the number of teeth is increased to big enough, the base circle diameter will
become smaller than than the diameter of dedendum circle. Then the gear profile will be all involute.
One can use similar approach given in this video for such case.

Figure 6: url: https://www.youtube.com/watch?v=0KOgNoIjYLE

This Video explains how one can model a spur gear with true involute profile teeth. It also explains
how one can use equations to make the gear Smarter in order to make it flexible from design point
of view. Later on, it shows how we can make different Configurations with few click and changes in
equation Box without any rebuild error.

4.2 Questions
1. Will SolidWorks and ANSYS give comparative results?

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2. Will the simulation output give comparative results to the theoretical values?

3. Should i simulate the lewis model primarily or the actuality model?

4. Why doesnt the Lewis model take into consideration stress concentrations?

4.3 Description of activities

Monday
1. Preparing for the meeting with my supervisor, while documenting progress made on the under-
standing of the research topic.

2. Working and completing tasks on Module 2 activities i.e Principles of Engineering research where
worked on how to:

Understand the principles research in relation to the phenomenon I am investigating

Understand the procedures on what type of data and evidence I would need for this research,
where I obtain this data, and how to determine if the data I am getting are relevant and
accurate.
Also completed task on developing a clear research question and hypothesis relevant to my
research area.
I also completed the tasks of understanding the scope of my research and completed the
facets of research in

Tuesday
1. Documenting down the list of questions and clarifications needed prior to the meeting with the
supervisor

2. Studied through the thesis named Stresses and deformations in involute spur gears by finite
element method

In this journal I understood how the variations of the whole gear body stiffness arising
from the gear body rotation due to bending deflection, shearing displacement and contact
deformation.
I also understood that mesh stiffness variation as the number of teeth in contact changes
is the primary cause of excitation of gear vibration and noise.
Discovered that in order to handle contact problems in meshing gears with the finite element
method, the stiffness relationship between the two contact areas is usually established
through a spring that is placed between the two contacting areas. This can be achieved by
inserting a contact element placed in between the two areas where contact occurs.

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Wednesday
1. Meeting with the supervisor

Presented the progress I have made on my research and asking clarifications on some un-
derstandings acquired.
Discussed with the supervisor for further areas I should concentrate on while carrying out
my research.
Discussed on the recommended methodology approach I should follow for the entire research
project.
The supervisor asked me to focus on relevant recent literature as obtained on online
databases duch as science direct, Scopus and Google scholar.
The supervisor committed to help me to obtain the softwares needed for the research.

Thursday
1. Studied through the journal Modeling and finite element analysis of spur gear

This research focuses on stress analysis of mating teeth of spur gear to find maximum
contact stress in the gear teeth.
I found out from this journal that the results from both Hertz equation and Finite Element
Analysis are comparable.
I also found out that Finite Element Method is the easy technique as compared to the
theoretical methods to find out the stress developed in a pair of gears.
I discovered that Fixed support is applied on inner rim of the lower gear. Frictionless
support is applied on the inner rim of upper gear to allow its tangential rotation but
restrict from radial translation.

Friday
1. Studied through the tutorial on Modeling an Equation Driven Involute Spur Gear in Solidworks

Supervisor Name Date & Signature

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5 Week 4
5.1 Simulations undertaken
5.1.1 Module
5.1.1.1 Module m = 8.3

Figure 7: ANSYS Equivalent Stress (Von-Mises) bending stress distribution for an involute spur gear
of module m = 8.3 and pressure angle = 20 .

Figure 8: SolidWorks Equivalent Stress (Von-Mises) bending stress distribution for an involute spur
gear of module m = 8.3 and pressure angle = 20 .

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5.1.1.2 Module m = 12.7

Figure 9: ANSYS Equivalent Stress (Von-Mises) bending stress distribution for an involute spur gear
of module m = 12.7 and pressure angle = 20 .

Figure 10: SolidWorks Equivalent Stress (Von-Mises) bending stress distribution for an involute spur
gear of module m = 12.7 and pressure angle = 20 .

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5.1.1.3 Module m = 17.5

Figure 11: ANSYS Equivalent Stress (Von-Mises) bending stress distribution for an involute spur gear
of module m = 17.5 and pressure angle = 20 .

Figure 12: SolidWorks Equivalent Stress (Von-Mises) bending stress distribution for an involute spur
gear of module m = 17.5 and pressure angle = 20 .

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5.1.1.4 Module m = 21.9

Figure 13: ANSYS Equivalent Stress (Von-Mises) bending stress distribution for an involute spur gear
of module m = 21.9 and pressure angle = 20 .

Figure 14: SolidWorks Equivalent Stress (Von-Mises) bending stress distribution for an involute spur
gear of module m = 21.9 and pressure angle = 20 .

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5.1.1.5 Module m = 26.3

Figure 15: ANSYS Equivalent Stress (Von-Mises) bending stress distribution for an involute spur gear
of module m = 26.3 and pressure angle = 20 .

Figure 16: SolidWorks Equivalent Stress (Von-Mises) bending stress distribution for an involute spur
gear of module m = 26.3 and pressure angle = 20 .

5.2 Description of activities

Monday
1. Updating of my logbook and reflective journal for review by my supervisor.
2. Studying through the topic Bending Stress Analysis & Optimization of Spur Gear where I
understood that

A minor drop in the root bending stress results in enormous enhancement in the bending
fatigue life of a spur gear.
By the means of stress relief features we can reduce the bending stress and increase the
fatigue life of spur gear

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Tuesday
1. Completion of Tasks in Module 3

Read through the guide of writing a literature review and using it to write the relevant
literature review relevant to my research.
Read through the Swinburne guide to misconduct and plagiarism and understanding how
important it is to my research.
Evaluated eight relevant references relevant to my research and analyze if it is good enough
for my research project.
Downloaded Endnote, which is a tool, used for managing references from various literatures,
and also went through the guide on how to setup library.

2. Preparation of meeting with supervisor.

Listing down the list of questions and findings to be presented to my supervisor.

Thursday
1. Studied through the journal titled Static analysis bending stress on gear tooth profile by vari-
ation of gear parameters with the help of FEA

The main objective of this paper is to analyze the bending stresses occur on the gear tooth
profile of gear used in gear box
Another objective is the effect on bending stress by variation of the gear parameters.
It was observed that gear having the face width 25 and root radius 4 produces minimum
bending stress.
I discovered that bending stresses at contact region decreases with increase the face width.
Also, bending stresses at contact region decreases with increase the root radius

Friday
1. Studied through the thesis titled Effect of change of spur gear tooth parameters on bending
and contact stresses

Shot peening is used to increase the tooth bending strength and surface durability in gears.
The surface roughness generated during shot peening leads to macro and micropitting is
now considered the dominant restriction on gear life and performance
It was observed that the maximum bending stress and contact stress decreases with in-
creasing face width, number of teeth and root fillet radius relative to spur gear set weight.
it is recommendable to use optimal values of tooth parameters during design work to reduce
stresses.
Stress reduction results in better tooth root load capacity, micropitting resistance, prolongs
gear service life

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Supervisor Name Date & Signature

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6 Week 5
6.1 b module results

108
Yield strength
ANSYS
Probe ANSYS
1.5 SolidWorks
Probe SW
theoretical
(Pa)

0.5

10 15 20 25
m (mm)

Figure 17: Plot of the bending stress distribution for = 20 and m = 8.30, 12.7, 17.5 ,21.9 and
26.3mm.

6.2 Questions
1. Why do the stresses in the gear not exceed the yield strength?

2. Why do ANSYS and SolidWorks bending stress results diverge at at every module value?

6.3 Description of activities

Monday
1. Commencement and completion of Module five activities, which focuses with developing research
methods and methodology, and I was able to

Develop a workable methodology for my project and create model and technique that best
suits my research process with relevant justification on the validity and reliabity.
I was able to analyze and conclude that my research requires a mixed methodology approach
of qualitative and quantitative.
I was able to conduct validity and reliability test in regards to my research project and
confirm the use of my developed methodology.

Tuesday
1. Updating my Logbook and for subsequent review by my supervisor

2. Preparation of meeting with my supervisor

Prepared a list of findings and questions to be presented to my supervisor.

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Preparation of a draft flow chart of my methodology for joint discussion with my supervisor.
Read online through Google search on materials relevant to developing methodology of spur
gear bending and contact stress research.

Wednesday
1. Meeting with supervisor

Discussed with my supervisor on my proposed research methodology.

Supervisor suggests in carrying out the research in various stages i.e. First by developing
a computational model for bending stress in FYRP1 and then a computational model for
contact stress in FYRP2.

Thursday
1. Studied and tried to evaluate the journal Effect of root radii on stress analysis of involute spur
gear under static loading

From this paper I learnt that the von-mises stresses and the deformation of the gears are
very much dependant on the root radius of the teeth.
The total deformation as well as von-mises stresses of the tooth directly dicreases as the
root radius increases.

Friday
1. Read through the journal Effect of pressure angle on bending stress and deformation of asym-
metric spur gear using FEA.

Asymmetric teeth with higher pressure angle on drive side have better performance than
symmetric teeth with common pressure angle 20 degree for bending stress minimization.
Bending stress is increased by 24% with 35 degree pressure angle on drive side than sym-
metric gear with 20 degree pressure angle.
As the pressure angle on drive side increases, the bending stress decreases and bending load
capacity increases.

Supervisor Name Date & Signature

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7 Week 6
7.1 Simulations undertaken
7.1.1 Pressure angle
7.1.1.1 Pressure angle = 14.5

Figure 18: ANSYS Equivalent Stress (Von-Mises) bending stress distribution for an involute spur gear
of = 14.5 and m = 12.7 mm

Figure 19: SolidWorks Equivalent Stress (Von-Mises) bending stress distribution for an involute spur
gear of = 14.5 and m = 12.7 mm

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7.1.1.2 Pressure angle = 20

Figure 20: ANSYS Equivalent Stress (Von-Mises) bending stress distribution for an involute spur gear
of = 20 and m = 12.7 mm

Figure 21: SolidWorks Equivalent Stress (Von-Mises) bending stress distribution for an involute spur
gear of = 20 and m = 12.7 mm

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7.1.1.3 Pressure angle = 25

Figure 22: ANSYS Equivalent Stress (Von-Mises) bending stress distribution for an involute spur gear
of = 25 and m = 12.7 mm

Figure 23: SolidWorks Equivalent Stress (Von-Mises) bending stress distribution for an involute spur
gear of = 25 and m = 12.7 mm

7.2 Description of activities

Monday
1. Read through the material Stress analysis of spur gear drive using finite element method by
varying pressure angle and understood

teeth with higher pressure angle have better performance than common pressure angles of
14.5, 20 degree for shear stress minimization.
The load capacity of the gear drive is increased by the pressure angle increased value.
As the pressure angle on increases, the bending stress decreases and bending load capacity
increases.

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Tuesday
1. Preparation for meeting with supervisor

Writing down various findings, questions and preparing amendments made for my method-
ology.

2. Engaging in Module 6 activities, which focuses on communication of findings.

Understanding and identifying various methods of communicating my research findings.

Understood how to present my findings to specific type of audience, in my own case students,
academics and researchers.
Selecting appropriate report structure and plan
Understanding how make oral presentation in reference in other to present my research
findings.

3. Completion of all module activities of semester 1

Wednesday
1. Meeting day with supervisor

Presentation of module activities for preliminary review

Presentation of progress and current findings
Discussion regarding research plan assessment
Discussion on recommended upcoming activity

2. Read through the paper Effect of pressure angle of spur gears on bending and contact stresses:
a comparative study using finite element software and understood that

With an increase in pressure angle (i.e from 14.5 to 30 degrees), there is a decrease in
bending stress.
With an increase in pressure angle (i.e from 14.5 to 30 degrees), there is a decrease in
contact stress.

Friday
1. Continued works on the preparing the research plan for submission next week.
2. Preparation of Gantt chart for semester 1 and 2
3. Preparation weekly outputs and outcomes schedule for the research plan.

Supervisor Name Date & Signature

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8 Week 7
8.1 b pressure angle results

108
Yield strength
ANSYS
Probe ANSYS
1.5 SolidWorks
Probe SW
theoretical
(Pa)

0.5

14 16 18 20 22 24 26
(deg)

Figure 24: Plot of the bending stress distribution for m = 12.7mm and = 14.5 , 20 and 25 .

8.2 Questions
1. Why do the stresses in the gear not exceed the yield strength?

2. Why do ANSYS and SolidWorks bending stress results diverge at at every pressure angle
value?

8.3 Description of activities

Monday
1. Completed work on the aims and objectives of my project

2. Refining the current progress of my literature review

Tuesday
1. Refining of research plan in preparation of for submission this week

2. Meeting with another senior currently taking FYRP2 for further discussion on the project.

3. Preparation of for the meeting with the supervisor.

Noting down questions and further confirmations required by me.

Read through again some of the past identified literature related to bending and contact
stress.

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Wednesday
1. Meeting with the supervisor

Discussed with him about newly acquired literature materials.

Thursday
1. Read through the technical report Effects of rim thickness on spur gear bending stress and
understood that

There is an increase in tensile and compressive bending stresses with decreasing backup
ratio.
Differences in the reported backup ratio at which the increases become measurable were
seen to depend primarily on rim support geometry.
The stiffer the rim support, the lower is the backup ratio at which the stresses increase over
those of a similar solid gear.

2. Submitted the softcopy of my research plan.

Friday
1. Read through the paper 3D contact stress analysis for spur gears and understood that

The stress distribution in the front plane for 3D model proves the same shape as the 2D
model stress distribution, but the values are smaller with 10%-15%.
The stress distribution along the face width proves to have the same shape as the load
distribution but NOT the same shape as the tooth edge deformations.
The stress increase significantly due to triangular load distribution, that means under non-
uniform contact conditions in the meshing process.

Supervisor Name Date & Signature

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9 Week 8
9.1 Simulations undertaken
9.1.1 Number of teeth
9.1.1.1 Number of teeth Np = 15

Figure 25: ANSYS Equivalent Stress (Von-Mises) bending stress distribution for an involute spur gear
of = 20 and Np = 15.

Figure 26: SolidWorks Equivalent Stress (Von-Mises) bending stress distribution for an involute spur
gear of = 20 and Np = 15.

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9.1.1.2 Number of teeth Np = 17

Figure 27: ANSYS Equivalent Stress (Von-Mises) bending stress distribution for an involute spur gear
of = 20 and Np = 17.

Figure 28: SolidWorks Equivalent Stress (Von-Mises) bending stress distribution for an involute spur
gear of = 20 and Np = 17.

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9.1.1.3 Number of teeth Np = 20

Figure 29: ANSYS Equivalent Stress (Von-Mises) bending stress distribution for an involute spur gear
of = 20 and Np = 20.

Figure 30: SolidWorks Equivalent Stress (Von-Mises) bending stress distribution for an involute spur
gear of = 20 and Np = 20.

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9.1.1.4 Number of teeth Np = 24

Figure 31: ANSYS Equivalent Stress (Von-Mises) bending stress distribution for an involute spur gear
of = 20 and Np = 24.

Figure 32: SolidWorks Equivalent Stress (Von-Mises) bending stress distribution for an involute spur
gear of = 20 and Np = 24.

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9.1.1.5 Number of teeth Np = 30

Figure 33: ANSYS Equivalent Stress (Von-Mises) bending stress distribution for an involute spur gear
of = 20 and Np = 30.

Figure 34: SolidWorks Equivalent Stress (Von-Mises) bending stress distribution for an involute spur
gear of = 20 and Np = 30.

9.2 Description of activities

Monday
1. Updated my logbook on my current progress

2. Worked on improving the content of reflective journal 2 due to submitted next week.

Tuesday
1. Preparation for the meeting with the supervisor

Documented the questions I need to ask him.

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Discussed with another research student, who is conducting different research and shared
ideas with him regarding model setups.

Wednesday
1. Studied through the paper Frictional contact stress analysis of spur gear by using Finite Element
Method and understood that

The contact stress increased with the increase of friction coefficient.

The contact stress decreased with the increase of face width, showing an inversely propor-
tional relation between them.

Thursday
1. Studied through the paper Bending Stress Analysis & Optimization of Spur Gear and under-
stood that

The trailing fillet which has compressive stresses has higher stress levels than the leading
fillet which has tensile stresses.
Keeping a hole along the profile of the tooth that the effect of any feature like a hole any
where above the dedendum and in the tooth leads to an increase in the stresses in the fillets.
The choice of the size and location of the elliptical hole is not a simple process, due to the
non linear variations in a complex geometry.
There is a general tendency to have a stress reduction by adding the circular hole.
The introduction of a elliptical hole or circular hole on the dedendum circle reduces the
stress levels by a very high percentage with a small loss of rigidity of the tooth.
This translates into an exponential increase in the life of the gear due to a better location
on the S-N curve for fatigue loading.

Friday
1. Studied through the paper Bending stress analysis of spur gear by using modified lewis formula

Torque decreases with increase in speed.

Bending stress increases with increase with tangential face.

Supervisor Name Date & Signature

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10 Week 9
10.1 b number of teeth results

108
4
Yield strength
ANSYS
Probe ANSYS
3 SolidWorks
Probe SW
theoretical
(Pa)

0
15 20 25 30

Np

Figure 35: Plot of the bending stress distribution for = 20 and Np = 15, 17, 20, 24 and 30.

10.2 Questions
1. Why is the stress in the gear with 15 number of teeth exceeding the yield strength?

2. Why do ANSYS and SolidWorks bending stress results diverge at number of teeth at 15, 17
and 20?

10.3 Description of activities

Monday
1. Updated my logbook on my current progress.

2. Derived expressions for the hertzian contact stress of a cylinder with respect to parameters such
as module, pressure angle and number of teeth.

Tuesday
1. Preparation of meeting with supervisor.

Noting down questions and further confirmations required by me.

Read through again some of the past identified literature.

2. Coded and plotted the derived expressions for the hertzian contact stress of a cylinder with
respect to parameters such as module, pressure angle and number of teeth.

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Wednesday
1. Meeting with my supervisor.

Presented the results of my hertzian contact stress distributions together with the mathe-
matica plots.
Supervisor noticed some errors especially on the curve, and asked me to double check my
code and calculations.

2. Went to the lab and studied the discrepancies between the mathematica plot and ANSYS sim-
ulations.

3. Found out that the hertizian contact stress distribution was off by a power of 102 Pa for both
the varrying number of teeth and module case because my module was in millimeters.

Thursday
1. Re-codded the derived expressions for the hertzian contact stress of a cylinder for the parameters,
module and number of teeth.

2. Read through the research article Frictional effects on gear tooth contact analysis and under-
stood that

The friction can decrease bending stress during the first contact phase, but the bending
stress will be increased due to friction during the second contact phase.
In static analysis, the friction can increase result values, but the noise will be decreased
slightly due to reliable friction.

Friday
1. Read through the journal paper Parametric stress analysis of spur gear tooth and understood
that

Contact stress decreases linearly as pressure angle increases.

Contact stress decreases linearly as face width increases.
On increasing transmission ratio corresponding pressure angle contact stress decreases.
But this difference is of very small magnitude in comparison with the actual stress values
and can be attributed to the difference in the theories involved.
To increase load carrying capacity of tooth pressure angle such be increased.
A shorter gear tooth will produce more concentrated areas of stress which is ideally avoided,
and should only be done if space is a major constraint.

Supervisor Name Date & Signature

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11 Week 10
11.1 Sketch 2

11.2 Questions
1. How do i simulate to actuality model?

2. Would the results from the actuality model yield similar results to the lewis model?

11.3 Description of activities

Monday
1. Prepared and updated my logbook

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2. Developing the subtopics and layout for the progress report.

3. Commenced writing of the progress report.

4. Commenced working on Introduction of my progress report.

Tuesday
1. Preparing for the meeting with Supervisor.

Preparing the progress report which included the compilation of the literature review,
introduction and current results and appendices.
Updating the contents of my literature review.

Wednesday
1. Meeting with supervisor

Presented the progress made on my progress report

2. Read through the thesis A comparison of the tooth-root stress and contact stress of an involute
spur gear mesh as calculated by FEM and AGMA standards and understood that

Bending stresses were very similar when compared between FEM and AGMA.
The contact analyses were not as accurate.
Finite element method should be used with caution when analyzing gears.
Static, implicit models provide good results when calculating static load cases with uniform
boundary conditions; However, most gear failures are the result of fatigue loading.
The AGMA equations are a more accurate tool when it comes to predicting gear failure as
they are based on empirical results from decades of data on gearing, and incorporate many
parameters that a finite element software package cannot.

Thursday
1. Read through the journal Frictional tooth contact analysis along line of action of a spur gear
using Finite element method and understood that

FE model results have a high degree of coincidence with the theoretical results.
The contact stress calculated for different coefficient of friction showed that the contact
stresses increased with the increasing value of static coefficient of friction. A 10% rise has
been observed when the friction coefficient value was increased from 0 to 0.3.
The increase in the contact stresses with the increase in friction coefficient provides with
an idea of friction factor to be incorporated while calculating the contact stress in meshed
gears.

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Friday
1. Read through the journal Non-Linear Contact Analysis of Meshing Gears and understood that

The contact between pinion and gear is highly non-linear because the surfaces of the tooth
could come into and out of contact in a sudden manner.
Fine tuning is required for the FEA model especially at the single tooth contact zone.
One of the ideal forms of comparison would be utilizing experimental testing.
Experimental activities are expensive and lengthy.

Supervisor Name Date & Signature

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12 Week 11
12.1 Recommended alternative model setup
12.1.1 ANSYS Workbench

Figure 36: ANSYS Workbench Depiction of the bending stress and contact stress distributions for an
involute spur gear of = 20 , Np = 18 and P = 2.

12.1.2 SolidWorks

Figure 37: SolidWorks Depiction of the bending stress and contact stress distributions for an involute
spur gear of = 20 , Np = 18 and P = 2.

12.2 Questions
1. Why dont the results from the actuality model yield similar results to the lewis model?

2. Are my models correct?

3. Is Lewis model invalid?

4. Why dont the contact stress values for SolidWorks and ANSY match?

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12.3 Description of activities

Monday
1. Updating and preparing workbook and reflective journal for submission.

2. Emailed my supervisor the completed simulation results.

3. Meet with the program convener to discuss about the outcome of my research plan assessment.

Tuesday
1. Analyzing my results and commenced the discussions.

2. Prepared a compiled draft progress report of all the progress made so far for presentation to my
supervisor tomorrow.

Wednesday
1. Meeting with supervisor.

Reported my findings regarding my discussion to the supervisor.

Discussed with the supervisor the format of making my discussions.
Discussed with him on how to properly write my abstract and introduction.
Discussed about the upcoming poster presentation in week 13
Discuss with him further about the overall expectations of the final progress report.

2. Continued work on the progress report.

Thursday
1. Read through the journal Experimental stress analysis spur gear using ansys software and
understood that

The parametric model is capable of creating spur gears with different modules and number
of teeth by modifying the parameters and regenerating the model.
It is possible to carry out finite element analysis such as root bending stress and contact
stresses between gear teeth pair and effect of root fillet radius on the root stresses.
Simulation results have good agreement with the theoretical results.

2. Continued work on the progress report and sent the current state to the supervisor.

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Friday
1. Read through the journal A finite element analysis of bending stresses induced in external and
internal involute spur gears and understood that

Maximum compressive fillet stresses decrease as the point of load application descends from
the highest point of tooth contact to the lowest contact for the meshing cycle.
Maximum tensile fillet stresses decrease as the load point descends the flank provided the
load point is remote from the fillet region. When load is applied near to the fillet region an
increase in the tensile fillet stresses attributed to proximity effects occurs.
As the point of load application descends the gear flank, the positions of maximum stress
in both tensile and compressive fillets move round the fillet in the same direction as the
load movement.
For loads applied at positions along the flank in approximately the top two-thirds of the
gear tooth the maximum compressive stress is greater than the maximum tensile stress.
This trend is reversed as the load point approaches the fillet.

Supervisor Name Date & Signature

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13 Week 12
13.1 Sketch 3

13.2 Questions
1. How do i simulate the hertzian contact stress model?

2. Is hertzian contact stress the same as hertzian contact pressure?

3. Will the hertzian contact stress model setup for a sphere and a flat plate be suitable for adoption
for two cylinders?

13.3 Description of activities

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Monday
1. Updated and prepared the logbook and reflective journal for submission.
2. Continued final work on finalizing the work on the progress report.

Tuesday
1. Preparation for the meeting with supervisor.

Completed and formatted the final progress report for discussion with the supervisor the
next day for a final review before submission.
Listing down question to ask the supervisor before final submission of the report.

2. Continued work on improving the progress report

Wednesday
1. Meeting with supervisor

Presented to him my own outline for the oral presentation.

Discussed on the poster for the presentation
Advised me on to conduct my upcoming presentation.
Asked for any necessary work to be done before submission of the progress report.

2. Working and preparing draft of my poster.

Thursday
1. Reviewed holistically the whole progress report before my scheduled submission tomorrow.
2. Showed an discussed with a senior Ph.D student my progress report and seeking his own com-
ments.

Friday
1. Submitted the progress report
2. Completed the final poster for the presentation
3. Final review of my Modules, workbook and reflective journal before hard copy submissions.

Supervisor Name Date & Signature

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14 Week 13
14.1 Hertzian contact stress model

Figure 38: von-misses equivalent stress ditribution for the hertzian contact stress of a cylinder 5 inches
in diameter with a 1 inch face width.

14.2 Videos

Figure 39: url: https://www.youtube.com/watch?v=zk4Xe_9AiKE

Step by step procedure of how to do static structural analysis of hertzian contact analysis ANSYS
13 workbench. We can also do wear analysis due to frictional rubbing between the contact surfaces.

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14.3 Documents

FEA Hands on Workshop

Hertian Contact

1 2011 ANSYS, Inc. July 1, 2013

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Workshop Goal and Procedure

Goal:
The purpose of this exercise is to demonstrate the simulation of the contact stress
between a loaded sphere and a flat plate:

Simple geometry was chosen because theoretical approximations are available.

Therefore the contact pressure can be calculated first by hand and then using the
Workbench Simulation module

Because the geometry is symmetric, only a quarter will be modelled to save

computational resources. Procedure:

2 2011 ANSYS, Inc. July 1, 2013

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Workshop Instructions

Follow numbered instructions

SC = Single Click with Left Mouse Button

DC = Double Click with Left Mouse Button
CtrlSC = Single Click with Left Mouse Button while press
Ctrl key
RMB = Right Mouse Button Selection

3 2011 ANSYS, Inc. July 1, 2013

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Hand Calculation
For Sphere on Plate with both material having same material
properties i.e. P = 400N

E = E1 = E2 = 2e5N / mm 2 K D = D = 200mm
D
= 1 = 2 = 0.3

PE 2
Max c = 0.6163
K D2
= 453.87 MPa

4 2011 ANSYS, Inc. July 1, 2013

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Step 1: Import Design Modeler file

1. Open new Workbench
Project
a) Open the DesignModeler File
Location >
Workshop>Hertian Contact
b) Select Sphere_plate.agdb
and Drag it to Project
Schematic
c) Note: Geometry Component
created in Project Schematic

5 2011 ANSYS, Inc. July 1, 2013

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Step 2: Save the Project

2. Save the project
a) On the Project Page> File>
Save
b) Browse for the folder
suggested by your instructor
and Save it as SpherePlate
c) Note: It will automatically
save it as Workbench Project
Files (*.wbpj)

6 2011 ANSYS, Inc. July 1, 2013

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Step 3: Save the Project

3. Save the project
a) Drag Static Structural from
the Analysis Systems and
Drag it on Geometry
b) Note: It will automatically
save it as Workbench Project
Files (*.wbpj)

7 2011 ANSYS, Inc. July 1, 2013

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Step 4: Open Mechanical Application

4. Open ANSYS Workbench
Mechanical application
RMB
a) Select Model RMB Edit

8 2011 ANSYS, Inc. July 1, 2013

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Step 5: Setup Project Unit System

5. Change unit system
a) Select Units
b) Choose Metric (mm, kg)

Note: This allows you to

enter dimensional values
in the unit system of
your choice.

9 2011 ANSYS, Inc. July 1, 2013

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Step 6: Check Materials Assigned

6. Check Material assigned
a) Click + to expand Geometry
branch in Outline tree.
b) Select part QUARTSPHERE[41]
c) Note: Material Assignment is
Structural Steel
d) Similarly check the Material
properties for QUARTPLATE[39]

10 2011 ANSYS, Inc. July 1, 2013

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Step 6: Check Materials Assigned

6. A) Check The Material assigned
a) Click + to expand Connection branch in
Outline tree.
b) Click + to expand Contacts
c) Select Contact Region
d) In the details window of the contact, Change
the Type of contact to Frictional and type in
Friction Coefficient = 0.3
e) Change the Behavior to Asymmetric
f) Set Update Stiffness to Each Iteration

11 2011 ANSYS, Inc. July 1, 2013

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Step 7: Check Contact

7. Check The Contact
a) Note the Contact and Target have 2
faces each
b) Zoom in to the Centre of contact region
c) Notice the Split Faces at the contact
location, This is done to specify meshing
control in that region

12 2011 ANSYS, Inc. July 1, 2013

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Step 8: Create Coordinate System

8. Create Coordinate System
a) Zoom in to the Centre where Sphere and
Ball meet
b) Select the Vertex filter
c) Select the vertex at the centre and use RMB
and Create Coordinate System
d) Click + to expand Coordinate Systems and
note the newly created Coordinate RMB
System

13 2011 ANSYS, Inc. July 1, 2013

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Step 9: Mesh Sizing

9. Specify Mesh Sizing
a) Select the Face filter
b) RMB on geometry and Select All to select
all faces
c) Select Mesh in the Outline tree and RMB >
Insert> Sizing
d) In the details of Face Sizing, use Type as
Sphere of Influence , Select Sphere Centre
as Coordinate System and specify
following values
a) Sphere Radius = 2 mm
b) Element Size = 0.1 mm

RMB

14 2011 ANSYS, Inc. July 1, 2013

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Step 9: Mesh Sizing

9.A Specify Mesh Sizing
a) Select the face of Plate part and
RMB Hide Body RMB
b) Zoom at the center of the Contact
Between the Sphere and Plate
c) Select the highlighted Face , RMB >
Insert> Sizing
d) In the details of newly added face
Sizing, Specify the Element Size of
0.01 mm
RMB

15 2011 ANSYS, Inc. July 1, 2013

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Step 10: Mapped Mesh

10. Specify Mapped Mesh Sizing
a)Select the highlighted face and RMB>
Insert Mapped Face Meshing
RMB
b)Select Mesh in Tree and RMB and
Generate Mesh
c)Have a look on refined mapped mesh
on the Sphere part, then RMB and Show
All Bodies

RMB

RMB

16 2011 ANSYS, Inc. July 1, 2013

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Step 11: Loads & Boundary Conditions

11. Apply Load on the sphere
a)Note: Since we are working on Quarter
model, We will apply of the total load
b)Select the Vertex filter
c)Select Static Structural

d)Select the Top vertex of the Sphere

part and RMB > Insert > Force

17 2011 ANSYS, Inc. July 1, 2013

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Step 11: Loads & Boundary Conditions

11. Apply Load on the sphere
a)In the Details window of Force
Select Defined By as Vector
b)Magnitude = 100 N
c)For Direction use the edge as
show
d)Use Toggle switch to change the
direction of force downward

18 2011 ANSYS, Inc. July 1, 2013

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Step 12: Loads & Boundary Conditions

12. Apply Fixed Support on base
of Plate
a)Select Face Filter
b)Select the highlighted bottom face of
the Plate and RMB> Insert> Fixed
Support

RMB

19 2011 ANSYS, Inc. July 1, 2013

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Step 13: Loads & Boundary Conditions

13. Symmetric Boundary
Condition
a)Select Symmetric Faces of Sphere and
Plate as Highlighted, RMB> Insert
frictionless Support
b)Note: There should be 8 faces, make
sure that you select small surfaces at
the tip of the contact

20 2011 ANSYS, Inc. July 1, 2013

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Step 14: Request Results

14. Request Result
a)Select Solution, RMB>
Insert >Deformation> Total RMB
b)Select Solution,
RMB> Insert >Stress>
Equivalent (Von-Mises)

RMB

21 2011 ANSYS, Inc. July 1, 2013

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Step 14: Request Results

RMB
14. Request Results
a)Select Solution, RMB>
Insert >Contact Tool>
Contact Tool

b)Select Contact Tool,

RMB> Insert >Pressure

RMB

22 2011 ANSYS, Inc. July 1, 2013

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Step 15: Solve

15. Solve
a)Select Solution, RMB>
Solve
b) Note: It will start solving
the model,
c)Select Solution
Information
d) In the Details of Solution
Information Select Solution
Output and change it to
Force Convergence

23 2011 ANSYS, Inc. July 1, 2013

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Step 16: Force Convergence Plot

16. Solve
a)Select Solution, RMB>
Solve
b) Note: It will start solving
the model,
c)Select Solution
Information
d) In the Details of Solution
Information Select Solution
Output and change it to
Force Convergence

24 2011 ANSYS, Inc. July 1, 2013

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Step 17: Post Processing Results

17. Post Processing
Results
a)Select Solution and
change the result to True
Scale
b)Select Total
Deformation to plot the
total deformation plot
c) Similarly Select
Equivalent Stress to plot
the equivalent stresses

25 2011 ANSYS, Inc. July 1, 2013

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Step 18: Post Processing Results

18. Post Processing
Contact Results
a)Click + to expand Contact
Tool in Outline tree.
b) Select Contact Pressure
to plot the Contact pressure
c)Compare it with the Hand
calculation in Slide 4

d)Note: the results is in

agreement with the hand
calculations

26 2011 ANSYS, Inc. July 1, 2013

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14.4 Websites
14.5 Questions
1. Why doesnt the prescribed model from Yang Caos video work?

2. Why do i have to result in using quarter cylinders to get comparative results to the theoretical?

3. Are there any advantages/disadvantages to using quarter cylinders?

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15 Relevant standards
15.1 Spur gear pressure angles

Figure 40: Values of Lewis form factor Y for standard spur gears (load applied at tip of the tooth).
Credit: Robert C. Juvinall and Kurt M. Marshek - Fundamentals of Machine Component Design, 5th
Edition pp 640.

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15.2 Actual sizes of gear teeth of various diametral pitches.

Figure 41: Diametral pitches of various actual gear sizes Note: In general, fine-pitch gears have P 20;
coarse - pitch gears have P 20. Credit: Robert C. Juvinall and Kurt M. Marshek - Fundamentals
of Machine Component Design, 5th Edition.

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15.3 Recommended alternative model setup

Figure 42: Alternative model setup.

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