Stress Distribution Estimation in Spur Gears Using the Lewis Equation-Based Design Algorithm

Abstract

For enhancing the performance and life of gears, an accurate estimate of stress distribution in spur gears is important. In this study, a systematic procedure is presented for estimating bending stress in spur gear teeth by using a design algorithm based on the Lewis equation. In this procedure, the gear spatial parameters, material data, and loading conditions are inserted into a computer framework to determine the maximum allowable stress at points along the tooth profile. Adjustments made to Lewis' equation account for the factors of shape and dynamic load and produce good results over previous conventional methods. Finite element analysis (FEA) was carried out to facilitate the illustration of stress contours in the engaged gear mesh and prove theoretical results. The comparison clearly supports a close degree of correlation between the analytical results and simulation results and demonstrates the application of the proposed algorithm. This work supports new advances in the technology of gear design by producing a consistent, well defined, and scalable process for stress analysis while specifically addressing the requirements of high-load mechanical systems and precision mechanical systems.