1. 2012 Japan-Taiwan iGO Symposium at NUU December 10-11,2012 Gear Design Method to contribute Global Environment and Resource Saving Oita National College of Technology Yusuke HASHIM TO 1/19 J09

2. 1. Introduction 2/19

3. 1. Introduction 3/19

4. 1. Introduction Key Shaft Keyway Gear Minimum Length c Tooth Bottom Bending Stress σ Empirical Formula : c >0.7 π m m: Gear Module Too large stress may lead to tooth failure. 4/19

5. 1. Introduction 5/19

6. 1. Introduction Iron Ores Mining in AUSTRALIA Oil Drilling in CHINA 6/19

7. To suggest a newly formula of minimum length c of gear with keyway 1. Introduction Object: Minimum Length c Bending Stress (Tensile) Bending Stress (Compressive) Gears meshing Load F n 7/19

8. 2. Methods of Experiment and Simulations 8/19

9. Standard Spur Gear Modulem6 Gear Teeth Numberz14 Pressure Angleα20° Tooth WidthB10mm Pitch Circle DiameterDpDp 84mm Tooth Bottom Circle DiameterDaDa 69mm MaterialS45C 2. Method of Experiment and Simulation 2.1 Gear Specifications DpDp DaDa B d d=28 d=36 d=44 d=48 d=52 =17.2mm =4.3mm Keyways are based on JIS(Japan Industrial Standard) 9/19

10. Center Line 30° Critical Section 30 degree tangent Fillet Curve 2. Method of Experiment and Simulation (1) Stress Measurement Point (2) Load Point and Value 2.2 Conditions B A 10/19

11. 2. Method of Experiment and Simulation (1) Stress Measurement Point (2) Load Point and Value 2.2 Conditions π m cos α Load Point F n =4000N Limit Fatigue Stress Bending Stress (Tensile) Bending Stress (Compressive) 11/19

12. 2. Method of Experiment and Simulation 2.3 Experiment Strain Gauges A B F n =4000N 12/19

13. 2.4 FEM Analysis 2. Method of Experiment and Simulation (1) Whole Gear Model Elements Number: 133075 Nodes Number: 211590 Elements Number: 97673 Nodes Number: 155922 Elements Number: 113454 Nodes Number: 182092 (2) Half Gear Model (3) Gear-Shaft Assembly Model : Fixed Geometry, Fixtures Type: Roller/Slider, Fixtures Type : Apply Mesh Control: No Penetration, Contact Type To analyze by the best suitable model for experiment results Gear hole diameter: d =28~52mm per 1mm intervals. 13/19

14. 3. Results and Discussion 14/19

15. 3. Results and Discussion 3.1 Experiment and FEM Analysis Results Experiment d=28 d=36 d=44 d=48 d=52 Constant Increase Tendency Influence Point of Keyway Bending Stress (Tensile) Bending Stress (Compressive) Minimum Dimension c d Fn 15/19

16. Gear-Shaft Assembly Model 3. Results and Discussion 3.1 Experiment and FEM Analysis Results σ=61d-108 σ=160d-711 σ=60.5d-107 σ=88d-272 Half Gear Model Whole Gear Model Experiment 16/19

17. 3. Results and Discussion 3.2 Simulation Result by the Gear-Shaft Assembly Model c >0.7 π m c >0.57 π m A possibility of 19% smaller design than gears up to now is confirmed. Tensile Stress Compressive Stress d Fn c =10.7mm, m =6 c =0.57 π m 17/19

18. 4. Conclusions 18/19

19. 4. Conclusions To suggest a newly formula of minimum length c of gear with keyway Object The newly formula is c >0.57 π m. A possibility of 19% smaller design than gears up to now is confirmed. Result To devise three analysis models and try to find which model result well corresponds to the experiment result. To calculate bending stresses by the best suitable model. Method Bending Stress (Tensile) Bending Stress (Compressive) Minimum Length c d Fn 19/19