Proceedings of ISERD International Conference, Istanbul, Turkey, 29th May 2016, ISBN: 978-93-85973-92-5

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A REVIEW ON DESIGN, ANALYSIS AND SHAPE OPTIMIZATION OF SPUR GEARS OF THE GEAR-BOX REDUCTION OF THE WORKING WHEEL OF THE EXCAVATOR SCHRS 1300 24/5.0 USING CAD/CAE

SOFTWARE

1FATMIR AZEMI, 2BEKIM MALOKU, 3MUSAJ TERBUNJA

1PhD student at Josip Juraj Strossmayer University Of Osijek, Mechanical Engineering Faculty- Slavonski Brod, Republic of Croatia, 2Teacher at Secondary Technical School “L.utfi Musiqi” Vushtrri-Republic of Kosovo

3Director in Department of Education in Municipality, Vushtrri-Republic of Kosovo E-mail: 1fatazemi@hotmail.com, 2bekim.m70@hotmail.com, 3musajterbunja@postribe.com

Abstract- Gears are one of the most important components in mechanical power transmission systems. The bending and surface strength of the gear tooth are considered to be one of the main contributors for the failure of the gear in gear set. The three dimensional solid model can be generated in CAD software, in this case we have created model in Autodesk Inventor 2015. This model of the spur gears are imported in ANSYS software and then contact stress and bending stress can be calculated in ANSYS. The paper presents the results of calculation of pair spur-gears that it used in the gear-box reduction of the working wheel of the Excavator located in open-cast coal mines in “Bardhi i Madh - Fushë Kosovë” , and after that will be optimized the shape of the spur gear with usage of ANSYS software. To be more specific, how much material can be removed from the gear body without compromising the gear meshing properties? Consequently, the aim of this research is to reduce weigh of the gears. Keywords- CAD/CAE software, FEM, Stress-Strain Analysis, Spur-Gear, Shape Optimization CAD-Computer Aided Design, CAE-Computer Aided Engineering, FEM-Finite Element Method I. INTRODUCTION Reduction of material has been one the critical aspects of any design along with reduction in deformation and stress factors, which increases the life of the product. Structural optimization tools like topology and shape optimization along with manufacturing simulation are becoming attractive tools in product design process. These tools also help to reduce product development time. This paper presents design, analysis and shape optimization in order to reduce material of spur gears and focuses on static analysis. Finite element analysis has been used to implement optimization and maintaining stress and deformation levels. II. STATEMENT OF THE PROBLEM, OBJECTIVES AND PURPOSE OF THE STUDY In the last published paper with titled “Stress-Strain Analysis of the Spur Gear of the Gear-box Reduction of the Working Wheel of the Excavator Schrs 1300 24/5.0 using CAD/CAE Software” we have presented the results of analysis of stress-strain of spur gear of the gear-box reduction of the Excavator. In that case we have found out that during Excavator arm movement from right side to left the bucket wheel works with maximum capacity and in that case have been caused damage in spur gear 9 and spur gear 10 of gear-box reduction of the Excavator. After the Stress-Strain Analysis of the Spur Gear, we found out that the Spur Gear didn’t accomplish working conditions with that geometry and material used, so,

our overall objective and purpose of this study is to determine: - which factors aren’t accomplished, - finding a solution that spur gear fulfill conditions,

and - shape optimization of the spur gear III. METHODOLOGY AND MATERIALS CAD is used mainly for the creation of detailed 3D solid or surface models, or 2D vector-based drawings of physical components. However, CAD is also used throughout the engineering process from conceptual design and layout of products, through strength and dynamic analysis of assemblies. In this case we have used CATIA V5, Autodesk Inventor Professional and ANSYS software for design, analysis and shape optimization of parts and their assembly. Based on the result from the last paper, in this paper first thing is to determine that, which conditions the spur gears didn’t fulfill. Autodesk Inventor professional 2015, Spur Gears Component Generator is used to generate a pair of gears with same geometry and material as shown below on tables. Method of Strength Calculation based on ISO 6336:1996. Parameters, geometrical data, materials and loads are given through tables as below:

Table 1. Common parameters:

A Review On Design, Analysis And Shape Optimization Of Spur Gears Of The Gear-Box Reduction Of The Working Wheel Of The Excavator Schrs 1300 24/5.0 Using Cad/Cae Software

Proceedings of ISERD International Conference, Istanbul, Turkey, 29th May 2016, ISBN: 978-93-85973-92-5

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Table 2. Main Geometrical Data of Gears

Fig,1. Section view of main geometrical data

Table 3. Loads

Table 4. Materials

A Review On Design, Analysis And Shape Optimization Of Spur Gears Of The Gear-Box Reduction Of The Working Wheel Of The Excavator Schrs 1300 24/5.0 Using Cad/Cae Software

Proceedings of ISERD International Conference, Istanbul, Turkey, 29th May 2016, ISBN: 978-93-85973-92-5

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Table 5. Factors

Table 6. Results

As we can see from table 6 these conditions the pair gears didn’t fulfill: - Factor of safety from Pitting is SH9=1.077 for Gear 9, - Factor of Safety from Tooth Breakage SF9=0.905 and SF10=0.905, - Static Safety in Contact SHst9=0.676 and SHst10=0.676. Based on the calculation from tables, numbers of teeth are commensurable but factors of safety presented that the pair gears must be check calculation, we can check material design or geometry design, but due to geometry of spur gears is depended from another pieces of gear-box reduction of the Excavator, we must choose to check material of gears. On tables 7 and 8 are shown results after checked material design of pair spur gears.

Fig.2. Teeth mesh after the pair of spur gears is generated

Solid generation the pair spur- gears is shown in fig.3.

Fig.3. The main generation of spur gears in Autodesk Inventor

Professional

This geometry of assembly could be transferred or redesign in any CAD software such as: CATIA, AutoCAD, Soldiworks, est. with the same dimensions. The analysis of design reviewed and shape optimization of spur gear are done with Finite Element Method – ANSYS software. IV. ANALYSIS AND SHAPE OPTIMIZATION OF SPUR GEAR WITH FINITE ELEMENT METHOD-ANSYS WORKBENCH Parametric design of spur gear 9 is built in CATIA V6 (fig.4) with the same dimensions taken from

A Review On Design, Analysis And Shape Optimization Of Spur Gears Of The Gear-Box Reduction Of The Working Wheel Of The Excavator Schrs 1300 24/5.0 Using Cad/Cae Software

Proceedings of ISERD International Conference, Istanbul, Turkey, 29th May 2016, ISBN: 978-93-85973-92-5

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model that is generated in Inventor Professional, and has been exported in ANSYS software for the analysis and shape optimization (fig.5,6).

Fig.4. Parametric design of spur gear 9 in CATIA

Fig.5. Meshed 3-D Model of Spur gear-ANSYS software

Fig.6. Red color shows zone that needed to be removed for

shape optimization

V. RESULTS AND DISCUSSION The gears (pinion and gear) are calculated in Inventor, the tools Spur Gears Component Generator has created components (fig.3) after application method of “Type of Strength Calculation-

Material Design”. Results are given on tables as below.

Table 7. Characteristics of Material after application method material design

A Review On Design, Analysis And Shape Optimization Of Spur Gears Of The Gear-Box Reduction Of The Working Wheel Of The Excavator Schrs 1300 24/5.0 Using Cad/Cae Software

Proceedings of ISERD International Conference, Istanbul, Turkey, 29th May 2016, ISBN: 978-93-85973-92-5

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Table 8. Results of spur gears in Inventor

Table 9. Mass reduction after the process of optimization – ANSYS software (FEM method)

Are designed three of different model geometries and evaluated in relation to static transmission using solver. The tooth geometry and load remained the same. A parametric model is shown in fig.7.

Fig. 7. Different model geometries after shape optimization-

CATIA V6 CONCLUSION They are a number of the components of the design process including calculations, material strengths, duty, and manufacture quality that are indicating in product development. In this paper geometry integration of the spur gear is used in order for relational design to be successfully implemented, all parts and products need to be parameterized. The spur gears geometry can be generated using mathematical calculations done in Autodesk Inventor professional and CATIA supports parametric design, through which gear geometry formula and relations are created. The model of spur gear 9 has been exported in ANSYS software for shape optimization. The design optimization helps in

reducing 20.5% of the structure weight (the initial and final mass of the spur gear are 669.58 kg and 538.48 kg, respectively), which in turn reduces the cost of the spur gear with safe design. Based on the results from shape optimization (fig. 6), the model of spur gear is redesign in CATIA V6 (fig.7). REFERENCES [1]. Simpson, T. W., Toropov, V., Balabanov, V., and Viana, F.

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