Fillet Profile Optimization for Maximum Bending Strength using Direct Gear Design Approach

  Balamurugan M,  Palani P. K.

Traditional standard gear design is based on a basic (or generating) gear rack. Parameters of this basic gear such as profile angle, addendum, and whole depth and fillet radius proportions were standardized. This made gear design indirect. Traditional gear design does not provide the best possible performance for any particular gear application because it is constrained by tooling parameter. Today we are forced to increase load carrying capacity, reduce transmission weight and fulfil noise requirements without increasing manufacturing cost High performance gears – aerospace and automotive, for example – do not use standard basic rack for design. Instead, they rely on custom racks which provide higher pressure angles or contact ratio. Direct gear design method introduces an alternative gear design approach to maximize gear drive performance in custom gear applications. It does not use tooling rack parameters. Instead, it defines gear shape based on required performance and operating conditions. It allows for the separation of the active involute flank and tooth fillet design. In this paper, gear pair for automotive gear box application was designed based on direct gear approach. The flank profiles were designed first to satisfy primary performance requirements. The tooth fillet design is based on completely defined involutes flank parameters. The initial fillet profile is a trajectory of the mating gear tooth tips in the tight mesh condition (zero backlashes). Fillet profile was optimized based on finite element analysis (FEA) and random search method so that to reduce the bending stress values in the fillet profile to obtain maximum load carrying capacity.

Keywords- Traditional gear design, Direct gear design, Fillet profile, FEA, Bending stress

Unique Identification Number - IJEDR1704164
Page Number(s) - 1009-1019
Pubished in - Volume 5 | Issue 4 | December 2017
DOI (Digital Object Identifier) -   
Publisher - IJEDR (ISSN - 2321-9939)

  Balamurugan M,  Palani P. K.,   "Fillet Profile Optimization for Maximum Bending Strength using Direct Gear Design Approach", International Journal of Engineering Development and Research (IJEDR), ISSN:2321-9939, Volume.5, Issue 4, pp.1009-1019, December 2017, Available at :http://www.ijedr.org/papers/IJEDR1704164.pdf