The Effect of Dimensional Accuracy on Gear Tooth Contact Stress Due to the Casting Process

Joao Bosco Belo; Natalino  Fonseca D. S. Guterres; Justiniano  S. Guterres; Lidio  I. Freitas; Lino  Mendonca

Joao Bosco Belo Department of Mechanical Engineering, Dili Institute of Technology, Ai Meti Laran Street, Dili, Timor Leste Dili Institute of Technology, Dili, Timor-Leste
Natalino Fonseca D. S. Guterres Department of Mechanical Engineering, Dili Institute of Technology, Ai Meti Laran Street, Dili, Timor Leste Dili Institute of Technology, Dili, Timor-Leste
Justiniano S. Guterres Department of Mechanical Engineering, Dili Institute of Technology, Ai Meti Laran Street, Dili, Timor Leste Dili Institute of Technology, Dili, Timor-Leste
Lidio I. Freitas Department of Mechanical Engineering, Dili Institute of Technology, Ai Meti Laran Street, Dili, Timor Leste Dili Institute of Technology, Dili, Timor-Leste
Lino Mendonca Department of Mechanical Engineering, Dili Institute of Technology, Ai Meti Laran Street, Dili, Timor Leste Dili Institute of Technology, Dili, Timor-Leste

Keywords: Spur Gear, Chilled Casting, Tooth Stress, Dimensional Accuracy

Abstract

Gear dimensional accuracy is principally determined by whether the teeth slip when the gear rotates at high speed. However, it is necessary to pay attention to the dimensions of the tooth profile during the gear production process. The casting method is one of the methods used in gear production for forming a tooth profile, which is then followed by the machining process and surface hardening as a finishing step. The thing that needs to be considered is dimensional accuracy, which greatly affects the contact stress and decreases transmission power. The research aims to analyze the surface hardness and contact stress through FEM after dimensional change due to casting. The casting material is nodular cast iron, the mold is made of silica sand, and it is in closed molding condition. The gear pattern is made of four parts with different dimensions. The surface of the gear tooth is characterized by a chill, so that the casting will run simultaneously with the surface hardening. Surface area occurs at a high hardness of 720 HV. The average error value for all gears is 0.023 mm, and the contact stress and safety factor values after the static simulation are above the average value of 1. These results still meet the standards permitted by ISO and ANSI/AGMA standards.

Downloads

Download data is not yet available.

References

Abedi H. R., Fareghi A., Saghafian H., and Kheirandish S. H., (2010) “Sliding wear behavior of a ferritic-pearlitic ductile cast iron with different nodule count,” Wear, vol. 268, no. 3–4, pp. 622–628.

AGMA 341.02, (1970) “Design of General Industrial Coarse Pitch Cylindrical Wormgearing” Design Manual for AGMA STANDARD, ANSI/AGMA., vol. 6022493. United State of America: AGMA Standard, p. 9.

Alhadeff L. L., Curtis D. T., Marshall M. B., and Slatter T., (2018) “The application of wire electrical discharge machining (WEDM) in the prototyping of miniature brass gears,” Procedia CIRP, vol. 77, no. Hpc, pp. 642–645.

ANSI/AGMA 2000-A88, (1988) “Gera classification and inspection Handbook: Tolerance and measuremnet methodes for unassembled spur and helical gears,” in Handbook, Partial Re., vol. 1988, no, AGMA Association, United State of America: American National Standard, p. 92-203.

ANSI/AGMA 2001-D04, (2004) “Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth,” vol. 04, p. 66.

ANSI/AGMA 2101-C95, (2001) “Fundamental Rating Factor and Calculation Methods for Involute Spur and Helical Gear Teeth”, Metric Edi. 2001, Alexandria, Virginia 22314: AGMA National Standard.

Artoni A., , Guiggiani M., Kahraman A. and Haryanto J., (2013) “Robust Optimization of Cylindrical Gear Tooth Surface Modifications Withing Ranges of Torque And Misalignments,” in Proceedings of the ASME 2013 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, vol. 77583, pp. 1–10.

Barglik J. et al., (2018) “Comparison of single and consecutive dual frequency induction surface hardening of gear wheels,” IOP Conf. Ser. Mater. Sci. Eng., vol. 355, no. 1.

Barka N., (2017) “Study of the machine parameters effects on the case depths of 4340 spur gear heated by induction—2D model,” Int. J. Adv. Manuf. Technol., vol. 93, no. 1–4, pp. 1173–1181.

Bodzás S., (2019) “Analysis of the effect of the addendum modification coefficient for contact surfaces of spur gear,” Stroj. Cas., vol. 69, no. 1, pp. 5–16.

Callister W. D. and Rethwisch D. G., (2010) Materials Science and Engineering An Intruduction, Eighth Edi. United States of America: Jhon Wiley and Sons, Inc, p. 402.

Bralla, J. G. (1986). Design For Manufacturability Handbook, Second Edi. McGraw-Hill, New York, NY 10011. United States of America, p. 689-704. www.digitalengineeringlibrary.com.

Cambell J., (2011) “Complete Casting Handbook Metal casting process, techniques and design”, First Edit. United State of America: Elsevier Ltd, p. 185-219.

Cao H. T., Dong X. P., Pan Z., Wu X. W., Huang Q. W. and Pei Y. T., (2016) “Surface alloying of high-vanadium high-speed steel on ductile iron using plasma transferred arc technique: Microstructure and wear properties,” Mater. Des., vol. 100, pp. 223–234.

Cardoso P. H. S., Israel, C. L. and Strohaecker, T. R., (2014) “Abrasive wear in Austempered Ductile Irons: A comparison with white cast irons,” Wear, vol. 313, no. 1–2, pp. 29–33.

Chaubey S. K. and Gupta K., (2022) “Sustainable Manufacturing of Asymmetric Miniature-Sized Ratchet Wheels by Wire Electrical Discharge Machining,” Machines, vol. 10, no. 7.

Conrado E., Gorla C., Davoli P., and Boniardi M., (2017) “A comparison of bending fatigue strength of carburized and nitrided gears for industrial applications,” Eng. Fail. Anal., vol. 78, pp. 41–54.

Cular I., Vučković K., Glodež S. and Tonković Z., (2022) “Computational model for bending fatigue prediction of surface hardened spur gears based on the multilayer method,” Int. J. Fatigue, vol. 161, p. 106892, Aug.

Davis J. R., (2005) Gear Materials, Properties, and Manufacture. United State of America: ASM International, p. 257-280.

Dommarco R. C. and Salvande J. D., (2003) “Contact fatigue resistance of austempered and partially chilled ductile irons,” Wear, vol. 254, no. 3–4, pp. 230–236.

Escobar A., Celentano D., Cruchaga M., and Schulz B., (2015) “On the effect of pouring temperature on spheroidal graphite cast iron solidification,” Metals (Basel)., vol. 5, no. 2, pp. 628–647.

Fu Y., Zhuo Y., Zhou X., Wan B., Lv H., and Wang Z., (2020) “Theoretical and experimental study on contact characteristics of spiral bevel gears under quasi-static and large loading conditions,” Appl. Sci., vol. 10, no. 15.

Gupta K. and Jain N. K., (2014) “On surface integrity of miniature spur gears manufactured by wire electrical discharge machining,” Int. J. Adv. Manuf. Technol., vol. 72, no. 9–12, pp. 1735–1745.

Gupta K. and Jain N. K.,, (2013) “Manufacturing of High Quality Miniature Gears by Wire Electric Discharge Machining,” no. February 2014, pp. 679–696.

Gupta K. R. L. and Jain N. K., (2017) “Advanced Gear Manufacturing and Finishing (Classical and Modern Processes)”. London-United Kingdom: Elsevier Ltd., p. 58-129.

Guterres N. D. F. S., Rusnaldy, Widodo A. and Syamsudin A., (2021a) “Investigate Temperature Preheating on the Chill Plate to Identify Surface Characteristic on the Ductile Iron by Sand Casting,” Int. J. Eng. Mater. Manuf., vol. 6, no. 3, pp. 141–151.

Guterres N. F. D. S., Rusnaldy and, and Widodo A., (2017a) “Gear distortion analysis due to heat treatment process,” in International Conference on Engineering, Science and Nanotechnology 2016 (ICESNANO 2016), vol. 1788.

Guterres N. F. D. S., Rusnaldy, and Widodo A., (2017b) “The Effect of Temperature in Induction Surface Hardening on the Distortion of Gear,” in IOP Conference Series: Materials Science and Engineering, vol. 202, no. 1.

Guterres N. F. D. S., Rusnaldy, Widodo A., and Carwita T., (2020b) “The effect of chills thickness to microstructure and surface hardness layer on specimen ductile cast iron,” in the 4Th International Conference on Materials and Metallurgical Engineering and Technology (Icommet) 2020 vol. 2384, no. December, p. 040004.

Hernández -G. C., Marín -G. R. M., Huertas-T. J. L., Efkolidis N., and Kyratsis P., (2016) “WEDM manufacturing method for noncircular gears, using CAD/CAM software,” Stroj. Vestnik/Journal Mech. Eng., vol. 62, no. 2, pp. 137–144, doi: 10.5545/sv-jme.2015.2994.

Hurst S., (1996) “METAL CASTING Appropriate technology in the small foundry”. London-UK: Intermediate Technology Publications Ltd, p. 123-148.

ISO 6336-1, (2007) “Calculation of load capacity of spur and helical gears: Basic principles, introduction and general influence factors,” in International Standard, Second edi., vol. 2007, Switzerland: ISO 2006, p. 109.

ISO 6336-2 (2006) “Calculation of load capacity of spur and helical gears: Calculation of load capacity of spur and helical gear”, International Organization for Standardization, vol. 3, p. 16.

ISO 6336-2, (2006) “Calculation of load capacity of spur and helical gears: Calculation of load capacity of spur and helical gear,” in International Standard, Second edi., vol. 2006, Switzerland: ISO 2006, p. 33.

ISO 6336-3, (2006) “Calculation of load capacity of spur and helical gears: Calculation of tooth bending strength,” in International Organization for Standardization, vol. 3, p. 33.

Beddoes J. and Bibby M. J., Princilpes of Metal Manufacturing Processes. Carleton University, Canada: Elsevier ButtenNorth-Heinemann p. 284-314.

Jafar K. A. and Behnam A. A., (2011) “Influence of Mold Preheating and Silicon Content on Microstructure and Casting Properties of Ductile Iron in Permanent Mold,” J. Iron Steel Res. Int., vol. 18, no. 3, pp. 34–39.

Jamari J., Ammarullah M. I., Afif I. Y., Ismail R., Tauviqirrahman M. and Bayuseno A. P., (2021) “Running-in analysis of transmission gear,” Tribol. Ind., vol. 43, no. 3, pp. 434–441.

Jaromin M., Dojka R., Jezierski J. and Dojka M., (2019) “Influence of type and shape of the chill on solidification process of steel casting,” Arch. Foundry Eng., vol. 19, no. 1, pp. 35–40.

Jenkins L. R., (2005) ASM Handbook, Volume 1, Properties and Selection: Irons, Steels, and High Performance Alloys, 10th Editi. United State of America: ASM Handbook,vol. 1, p. 284-314.

Jolivet S., Mezghani S., Mansori E., and Zahouani H., (2013) “Gear noise behavior induced by their topological quality,” Surf. Topogr. Metrol. Prop., vol. 2, no. 1, p. 014008, Dec.

Kanthavel K., Arunkumar K., and Vivek S., (2014) “Investigation of chill performance in steel casting process using Response Surface Methodology,” Procedia Eng., vol. 97, pp. 329–337.

Kayabasi O. and Erzincanli F., (2007) “Shape optimization of tooth profile of a flexspline for a harmonic drive by finite element modelling,” Mater. Des., vol. 28, no. 2, pp. 441–447.

Keyence India PVT. LTD., (2022) “KEYENCE INDIA PVT. LTD”, https://www.keyence.co.in/, 2022. [Online]. Available: https://www.keyence.co.in/. [Accessed: 11-Sep-2022].

Kolivand M. and Kahraman A., (2009) “A load distribution model for hypoid gears using ease-off topography and shell theory,” Mech. Mach. Theory, vol. 44, no. 10, pp. 1848–1865.

Komori M. et al., (2009) “Evaluation method of lead measurement accuracy of gears using a wedge artefact,” Meas. Sci. Technol., vol. 20, no. 2.

Korta J. A. and Mundo D., (2017) “Multi-objective micro-geometry optimization of gear tooth supported by response surface methodology,” Mech. Mach. Theory, vol. 109, no. June 2016, pp. 278–295.

Kumar M., Ahmad S., and Das M., (2021) “Magnetorheological-finishing of miniature gear teeth profiles using uniform flow restrictor”, vol. 37, no. 4, pp. 467–482.

Kumar P., Sairam C., Hussain M., and Srivastava J. P., (2022) “Investigation on effects of variation of applied load on helical bevel gear made of different materials using simulation technique”, Mater Today Proc., Jul. 2022.

Lawson E., (2004) “ANSI/AGMA Accuracy Standards for Gears,” Gear Technol., vol. 21, no. 2, pp. 22–26.

Mehr F. F., Reilly C., Cockcroft S., Maijer D., and Mackay R., (2014) “Effect of chill cooling conditions on cooling rate, microstructure and casting/chill interfacial heat transfer coefficient for sand cast A319 alloy,” vol. 27, no. 5.

Mott R. L., (2004) Machine Elements in Mechanical Design, Fourth Edi. United States of America: Pearson Education, Inc., Upper Saddle River, New Jersey 07458, p. 306-308.

Nisbett B., (2006) Mechanical Engineering : Shigley’s Mechanical Engineering Design, 8th Editio. United State of America: A Division of The Mc Graw Hill Companies, p. 654-718.

Olawale J. O., Ibitoye, S. A., and Oluwasegun, K. M., (2016) “Processing Techniques and Productions of Ductile Iron: A Review,” Int. J. Sci. Eng. Res., vol. 7, no. 9, ISSN 2229-5518, pp. 397–423.

Pavitra H. S. and Anatha P. M. G., (2018) “Study on Microstructure and Mechanical Properties of Al/SiO2/C hybrid metal matrix composite, with the Influence of Chills,” Mater. Today Proc., vol. 5, no. 2, pp. 6053–6058.

Flood S. C., et al. 1998, ASM Handbook Vol. 15, “Casting”. United State of America: ASM International, University of Oxford, Great Britain. p. 284.

Qian M., Harada S., Kuroshima Y., and Ngayoshi H., (1996) “Surface hardening of ductile cast iron using stainless steel,” Mater. Sci. Eng. A, vol. 208, no. 1, pp. 88–92.

Radzevich S. P., (2012), “Practical Gear Design and Manufacture”, Second Edi. Boca Raton London New York: CRC Press Taylor & Francis Group p. 307-368.

Schneider T., Müller D., Seiler M., Tobie T., Stahl K., and Kästner M., (2022) “Phase-field modeling of fatigue crack growth during tooth flank fracture in case-hardened spur gears,” Int. J. Fatigue, vol. 163, p. 107091, Oct. 2022.

Sohi M. H., Ebrahimi M., Ghasemi H. M., and Shahripour A., (2012) “Microstructural study of surface melted and chromium surface alloyed ductile iron,” Appl. Surf. Sci., vol. 258, no. 19, pp. 7348–7353.

Stöbener D., Freyberg A. V., Fuhrmann M., and Goch G., (2012) “Areal parameters for the characterisation of gear distortions,” Materwiss. Werksttech, vol. 43, no. 1–2, pp. 120–124.

Sularso and Suga K., (2004) “Dasar Perencanaan dan Pemilihan Elemen Mesin”, 11th ed. Jakarta: PT. Pradnya Paramita, Jakarta, p.300.

Von F. A.. and Marc Pillarz A. F., (2020) “Gear shape parameter measurement using a model-based scanning multi-distance measurement approach,”Sensors (Switzerland), vol. 20, no. 14, pp. 1–16.

Wang J. et al., (2021) “Mathematical simulation and experimental verification of carburizing quenching process based on multi-field coupling,” Coatings, vol. 11, no. 9.

Wankhede D. M., Narkhede B. E., and Mahajan S. K., (2017) “Investigation of Casting Parameters and External Chills Performance onMechanical Properties of Aluminum Silicon Alloy (LM6) Castings,” no. 7, pp. 4–8.

Wankhede D. M., Narkhede B. E., Mhajan S. K., and Choudhari C. M., (2018) “Influence of pouring temperature and external chills on mechanical properties of aluminum silicon alloy castings,” Mater. Today Proc., vol. 5, no. 9, pp. 17627–17635.

Washko S. D. and Aggen G., (1993) ASM Handbook Vol. 1 Properties and Selection: Irons Steels and High Performance Alloys, 10 Edition. United State of America: ASM International, p. 2006-2021.

Callister W. D., and Rethwisch Jr. D. G. (2010). Material Science and Engineering An Introduction Eigth Ed. John Wiley & Sons, Inc. United States of America. p. 402-405. https://www.wiley.com/en-us/permissions.

Yao Y., Chen X., Xing J., Shi L. and Wang Y., (2021) “Tooth Position and Deformation of Flexspline Assembled with Cam in Harmonic Drive Based on Force Analysis,” Chinese J. Mech. Eng. (English Ed., vol. 34, no. 1.

Zhang Y., Wang G., Pan X., and Li Y., (2022) “Calculating the Load Distribution and Contact Stress of the Disposable Harmonic Drive under Full Load,” Machines, vol. 10, no. 2.