Abstract
Stresses occurring at the gear root are critical for the durability and lifespan of the gear. High stress concentrations can lead to fatigue and failure; therefore, accurate analysis of these stresses is essential. In this study, the placement of stress relief holes to reduce root stresses in spur gears was investigated using the finite element method. The gear geometries were modeled and analyzed in ANSYS Workbench. The study was conducted in three phases: firstly, 15 models were analyzed by varying the hole diameter and center distance at five and three levels, respectively, for a single hole; secondly, 27 analyses were performed for double-hole configurations by varying hole diameter, distance from the root circle, and central angle at three levels each; finally, the effect of different cutting tool tip radii on the optimal hole configuration was examined. The results revealed that increasing hole diameter and center distance significantly increased the stress values. For double-hole cases, positioning the holes at a certain distance from the root circle and using larger central angles contributed to stress reduction. However, variations in cutting tool tip radius had no significant effect on the performance of stress relief holes. Overall, it was concluded that the introduced stress relief holes had no substantial impact on reducing root stresses across the examined scenarios.
References
- Abu-Hamdeh, N.H. ve Alharthy, M. (2014). Application of finite element to spur gear stress reduction using stress relieving feature, Applied Mechanics and Materials, 575, 296–299. doi:10.4028/www.scientific.net/amm.575.296
- Babalık, F.C. ve Çavdar, K (2018) Makine elemanları ve konstrüksiyon örnekleri, Dora, Bursa.
- Cavdar, K., Karpat, F. ve Babalik, F. C. (2004). Computer aided analysis of bending strength of involute spur gears with asymmetric profile, Journal of Mechanical Design, 127(3), 477–484. doi:10.1115/1.1866158
- Costopoulos, TN. ve Spitas V. (2009). Reduction of gear fillet stresses by using one-sided involute asymmetric teeth, Mechanism and Machine Theory, 44,(8), 1524-1534. doi:10.1016/j.mechmachtheory.2008.12.002.
- DIN3990 (1987) – Calculation of load capacity of cylindrical gears: Calculation of tooth strength.
- Chavan, U.J., Shitole, J.S. ve Kathale, S.S. Analysis and optimization of contact stresses in spur gear using finite element analysis, International Journal of Engineering Research & Technology, 13(3), 1-6. doi:10.17577/IJERTV13IS030212
- Doğan, O., Yılmaz, T. G. ve Karpat, F. (2018). Farklı parametrelere sahip evolvent düz dişli çarkların sonlu elemanlar yöntemi ve grafik metot ile gerilme analizi, Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, 33, 1493–1504. doi:10.17341/gazimmfd.416445
- Francesco, GD. ve Marini S. (2007) Asymmetric teeth: Bending stress calculation, Gear Technology, 24: 52-55.
- Fredette, L. ve Brown, M. (1997). Gear stress reduction using internal stress relief features, Journal of Mechanical Design, 119(4), 518–521. doi:10.1115/1.2826398
- ISO 6336 (2002) – Calculation of load capacity of spur and helical gears - Application for industrial gears.
- Patil, S. S., Karuppanan, S., ve Atanasovska, I. (2016). Experimental measurement of strain and stress state at the contacting helical gear pairs. Measurement, 82, 313–322. doi:10.1016/j.measurement.2015.12.046
- Pedersen NL. (2010). Improving bending stress in spur gears using asymmetric gears and shape optimization, Mechanism and Machine Theory, 45(11), 1707-1720. doi:10.1016/j.mechmachtheory.2010.06.004
- Savran, E ve Karpat, F. (2024) Tooth root stress relief hole optimization on the spur and helical gears, International Journal of Advanced Natural Sciences and Engineering Researches, 8, 343-352.
- Senthil Kumar, M., Santhosh, M., Arvind, E., Ashwin, M. ve Prashant, S. (2017). Optimization of spur gear design to reduce stress, Applied Mechanics and Materials, 867, 220–227. doi:10.4028/www.scientific.net/amm.867.220
- Spitas, V. ve Spitas, C. (2007) Optimizing involute gear design for maximum bending strength and equivalent pitting resistance. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 221, 479–488. doi:10.1243/0954406JMES342
- Van Thoan, P., Wen, G., Yin, H., Ld, H. ve Sy Nguyen, V. (2015). Optimization design for spur gear with stress-relieving holes, International Journal of Computational Methods, 12(02), 1550006. doi:10.1142/s0219876215500061
- Vigneshwaran, K., Shanmugam, D. Ve Balasuthagar, C. (2020). Experimental and analytical stress analysis of spur gear, IOP Conference Series: Materials Science and Engineering, 912(2), 022043. doi:10.1088/1757-899x/912/2/022043
- Zhou, W., Zhu, R., Li, Z., Liu, W., Wang, J., ve Mu, F. (2024). Theoretical and experimental research on tooth root bending stress of face gear. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 238(14), 7172–7188. doi:10.1177/09544062241228009
Abstract
Diş dibinde oluşan gerilmeler, dişlinin dayanıklılığı ve ömrü açısından kritik öneme sahiptir. Yüksek gerilmeler, erken yorulma ve hasara yol açabileceğinden, bu gerilmelerin doğru analiz edilmesi gereklidir. Bu çalışmada, düz dişli çarklarda diş dibi gerilmelerini azaltmak amacıyla gerilme giderme deliklerinin konumlandırılması sonlu elemanlar yöntemiyle incelenmiştir. Oluşturulan dişli geometrileri, ANSYS Workbench’te analiz edilmiştir. Çalışma üç aşamada gerçekleştirilmiştir: İlk olarak, tek delik için delik çapı ve merkez uzaklığı parametreleri beş ve üç farklı seviyede değerlendirilerek 15 model analizi yapılmıştır. İkinci aşamada, çift delik için delik çapı, diş dibi dairesine uzaklık ve merkez açısı üç seviyede incelenmiş, toplam 27 analiz gerçekleştirilmiştir. Son aşamada ise, optimum delik konfigürasyonu üzerinde farklı kesici takım uç yarıçaplarının gerilme üzerindeki etkisi araştırılmıştır. Analiz sonuçları, delik çapı ve merkez uzaklığının artmasının gerilme değerlerini belirgin şekilde yükselttiğini ortaya koymuştur. Çift delik senaryolarında, deliklerin diş dibinden belirli bir uzaklığa konumlandırılması ve geniş merkez açıları gerilme azaltımını desteklemiştir. Kesici takım uç yarıçapı değişiminin ise gerilme giderme performansı üzerinde anlamlı etkisi olmadığı bulunmuştur. Sonuç olarak incelenen üç senaryo için de açılan gerilme giderme deliklerinin gerilme düşüşü üzerinde belirgin bir etkiye sahip olmadığı tespit edilmiştir.
References
- Abu-Hamdeh, N.H. ve Alharthy, M. (2014). Application of finite element to spur gear stress reduction using stress relieving feature, Applied Mechanics and Materials, 575, 296–299. doi:10.4028/www.scientific.net/amm.575.296
- Babalık, F.C. ve Çavdar, K (2018) Makine elemanları ve konstrüksiyon örnekleri, Dora, Bursa.
- Cavdar, K., Karpat, F. ve Babalik, F. C. (2004). Computer aided analysis of bending strength of involute spur gears with asymmetric profile, Journal of Mechanical Design, 127(3), 477–484. doi:10.1115/1.1866158
- Costopoulos, TN. ve Spitas V. (2009). Reduction of gear fillet stresses by using one-sided involute asymmetric teeth, Mechanism and Machine Theory, 44,(8), 1524-1534. doi:10.1016/j.mechmachtheory.2008.12.002.
- DIN3990 (1987) – Calculation of load capacity of cylindrical gears: Calculation of tooth strength.
- Chavan, U.J., Shitole, J.S. ve Kathale, S.S. Analysis and optimization of contact stresses in spur gear using finite element analysis, International Journal of Engineering Research & Technology, 13(3), 1-6. doi:10.17577/IJERTV13IS030212
- Doğan, O., Yılmaz, T. G. ve Karpat, F. (2018). Farklı parametrelere sahip evolvent düz dişli çarkların sonlu elemanlar yöntemi ve grafik metot ile gerilme analizi, Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, 33, 1493–1504. doi:10.17341/gazimmfd.416445
- Francesco, GD. ve Marini S. (2007) Asymmetric teeth: Bending stress calculation, Gear Technology, 24: 52-55.
- Fredette, L. ve Brown, M. (1997). Gear stress reduction using internal stress relief features, Journal of Mechanical Design, 119(4), 518–521. doi:10.1115/1.2826398
- ISO 6336 (2002) – Calculation of load capacity of spur and helical gears - Application for industrial gears.
- Patil, S. S., Karuppanan, S., ve Atanasovska, I. (2016). Experimental measurement of strain and stress state at the contacting helical gear pairs. Measurement, 82, 313–322. doi:10.1016/j.measurement.2015.12.046
- Pedersen NL. (2010). Improving bending stress in spur gears using asymmetric gears and shape optimization, Mechanism and Machine Theory, 45(11), 1707-1720. doi:10.1016/j.mechmachtheory.2010.06.004
- Savran, E ve Karpat, F. (2024) Tooth root stress relief hole optimization on the spur and helical gears, International Journal of Advanced Natural Sciences and Engineering Researches, 8, 343-352.
- Senthil Kumar, M., Santhosh, M., Arvind, E., Ashwin, M. ve Prashant, S. (2017). Optimization of spur gear design to reduce stress, Applied Mechanics and Materials, 867, 220–227. doi:10.4028/www.scientific.net/amm.867.220
- Spitas, V. ve Spitas, C. (2007) Optimizing involute gear design for maximum bending strength and equivalent pitting resistance. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 221, 479–488. doi:10.1243/0954406JMES342
- Van Thoan, P., Wen, G., Yin, H., Ld, H. ve Sy Nguyen, V. (2015). Optimization design for spur gear with stress-relieving holes, International Journal of Computational Methods, 12(02), 1550006. doi:10.1142/s0219876215500061
- Vigneshwaran, K., Shanmugam, D. Ve Balasuthagar, C. (2020). Experimental and analytical stress analysis of spur gear, IOP Conference Series: Materials Science and Engineering, 912(2), 022043. doi:10.1088/1757-899x/912/2/022043
- Zhou, W., Zhu, R., Li, Z., Liu, W., Wang, J., ve Mu, F. (2024). Theoretical and experimental research on tooth root bending stress of face gear. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 238(14), 7172–7188. doi:10.1177/09544062241228009
Details
| Primary Language | Turkish |
|---|---|
| Subjects | Automotive Engineering (Other) |
| Journal Section | Research Article |
| Authors | |
| Submission Date | July 21, 2025 |
| Acceptance Date | October 13, 2025 |
| Early Pub Date | December 11, 2025 |
| Publication Date | December 19, 2025 |
| Published in Issue | Year 2025 Volume: 30 Issue: 3 |
Cite
Announcements:
30.03.2021-Beginning with our April 2021 (26/1) issue, in accordance with the new criteria of TR-Dizin, the Declaration of Conflict of Interest and the Declaration of Author Contribution forms fulfilled and signed by all authors are required as well as the Copyright form during the initial submission of the manuscript. Furthermore two new sections, i.e. ‘Conflict of Interest’ and ‘Author Contribution’, should be added to the manuscript. Links of those forms that should be submitted with the initial manuscript can be found in our 'Author Guidelines' and 'Submission Procedure' pages. The manuscript template is also updated. For articles reviewed and accepted for publication in our 2021 and ongoing issues and for articles currently under review process, those forms should also be fulfilled, signed and uploaded to the system by authors.