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