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Optimization of contact stress for the high contact ratio spur gears achieved through novel hob cutter

Optimierung der Kontaktspannung für Stirnräder mit hohem Kontaktverhältnis durch neuartigen Wälzfräser

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Abstract

High contact ratio gears are used to minimize the stresses generated on the tooth surface. This research article represents an idea to enrich the contact strength of gear drive using novel high contact ratio (NHCR) spur gear. The increase in contact stress leads to contact fatigue failure, reducing the power transmission capacity of the gear drive. To reduce contact fatigue failure, contact stress needs to be reduced. A high contact ratio spur gear is developed using the novel hob cutter with variable tooth thickness to minimize the contact stress. For a novel hob cutter, the tooth thickness coefficient is greater than 0.5, while the thickness factor of a conventional hob cutter is 0.5. The maximum contact stress is determined through finite element analysis. In addition, a parametric study is executed for the gear parameter such as gear ratio, gear teeth, pressure angle, addendum factor and addendum correction factor to determine optimum contact stress.

Zusammenfassung

Zahnräder mit hoher Überdeckung werden verwendet, um die an der aktiven Zahnflanke vorliegende Beanspruchung zu minimieren. Dieser Forschungsartikel stellt eine Idee vor, die Grübchentragfähigkeit einer Verzahnung durch die Verwendung von Stirnrädern mit großer Profilüberdeckung zu steigern. Der Anstieg der Kontaktspannung führt zu Wälzermüdung und verringert die Leistungsfähigkeit des Zahnradantriebs. Um die Wälzbeanspruchung zu reduzieren, muss die Kontaktspannung reduziert werden. Es werden Stirnräder mit hoher Überdeckung betrachtet, wobei diese unter Verwendung eines neuartigen Wälzfräsers mit variabler Zahndicke erzeugt wurden, um die Kontaktbeanspruchung zu minimieren. Bei dem verwendeten, neuartigen Wälzfräser ist der Zahndickenkoeffizient größer als 0,5, während der Zahndickenkoeffizient eines herkömmlichen Wälzfräsers 0,5 beträgt. Die maximale Kontaktspannung wird durch Finite-Element-Analyse bestimmt. Darüber hinaus wird eine Parametervariation für die Verzahnungsgrößen Übersetzungsverhältnis, Zähnezahl, Eingriffswinkel, Profilverschiebung und Kopfhöhenfaktor durchgeführt, um die optimale Kontaktspannung zu bestimmen.

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Acknowledgements

The authors are grateful to Science & Engineering Research Board, India, for providing a funding grant (File No. ECR/2017/000425) to carry out this research work.

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  1. School of Mechanical Engineering, SASTRA Deemed to be University, Thanjavur, India

    S. Rajesh, P. Marimuthu & P. Dinesh Babu

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  1. S. Rajesh
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Correspondence to P. Marimuthu.

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S. Rajesh, P. Marimuthu and P. Dinesh Babu declare that they have no competing interests.

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Rajesh, S., Marimuthu, P. & Dinesh Babu, P. Optimization of contact stress for the high contact ratio spur gears achieved through novel hob cutter. Forsch Ingenieurwes 86, 123–131 (2022). https://doi.org/10.1007/s10010-022-00577-z

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