Gear Design M ethod to contribute Global Environment and Resource Saving

1. 2012 Japan-Taiwan iGOSymposium at NUUDecember 10-11,2012 J09 Gear Design Method to contribute Global Environment and Resource Saving YusukeHASHIM TO Oita National College of Technology 1/19

2. 1. Introduction 2/19

3. 1. Introduction Certainty High Reliability 3/19

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

5. 1. Introduction Downsizing Lightening 5/19

6. 1. Introduction Resource Saving Iron OresMiningin AUSTRALIA Oil Drilling in CHINA 6/19

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

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

9. 2. Method of Experiment and Simulation 2.1 Gear Specifications Dp Da ℓ d B ℓ =4.3mm ℓ =17.2mm d=36 d=44 d=52 d=48 d=28 9/19 ※Keyways are based on JIS(Japan Industrial Standard)

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

11. 2. Method of Experiment and Simulation 2.2 Conditions Stress Measurement Point Load Pointand Value πm cos α Fn =4000N Load Point Ｂ Ａ Bending Stress (Compressive) Limit Fatigue Stress Bending Stress (Tensile) 11/19

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

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

14. 3. Results and Discussion 14/19

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

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

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

18. 4. Conclusions 18/19

19. 4. Conclusions To suggest a newly formula of minimum length ℓcof gear with keyway The newly formula is ℓc >0.57πm. A possibility of 19% smaller design than gears up to now is confirmed. Object Result Fn Method Bending Stress (Compressive) d 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. Bending Stress (Tensile) Minimum Length ℓc 19/19