ANALYSIS ON FATIGUE WEAR AND WEIGHT REDUCTION OF GEARS USED IN HEAVY DUTY VEHICLES

Abstract

In this work it is planned to investigate the effect of tooth contact on strength and basic performance parameters of gears. Very often the vehicles are facing gear failure in heavily loaded gears. Weight reduction is the important factor which can attract the customer. Since we know that reduction of weight in any component in the system without making hazardous to it, leads to reduce the weight, instead we have removed optimum amount of material in the teeth such that the performance of gear is undisturbed. Since we remove the material of required amount near the teeth and analysis it, we got surprising results when we tried this out with various geometrical cross sections such as circle, square, rectangle, triangle and hexagon. Interestingly, we found that circular cross section gives better results than others. Then we

proceeded with two case studies – Positioning and Sizing and obtained the desired results. The whole work is done with CAE tool ANSYS 12 (for modeling and analysis).The results are presented and discussed with graphical comparisons Based on the results obtained from experimental and theoretical analysis it is proposed to recommend a new design for gear which capable to withstanding fatigue wear.

Author

P.L.Srenatthan , P.Vignesh