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

[+] Author and Article Information
Vasilios A. Spitas, Christos A. Spitas

Laboratory of Machine Elements, National Technical University of Athens, Iroon Politechniou 9, 15780, Athens, Greece

Theodore N. Costopoulos1

Laboratory of Machine Elements, National Technical University of Athens, Iroon Politechniou 9, 15780, Athens, Greececost@central.ntua.gr


Corresponding author.

J. Mech. Des 128(5), 1159-1164 (Nov 27, 2005) (6 pages) doi:10.1115/1.2216731 History: Received March 09, 2005; Revised November 27, 2005

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

Copyright © 2006 by American Society of Mechanical Engineers
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Figure 2

The optimization algorithm

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Figure 3

Nondimensional root stress for z1=12 pinion teeth

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Figure 4

(%) Reduction of the root stress for optimum gears (pinion with 12 teeth)

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Figure 5

Photoelastic fringe patterns on sample gear-tooth models




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