DESIGN & ANALYSIS OF SINGLE STAGE … & ANALYSIS OF SINGLE STAGE INDUSTRIAL HELICAL ... of a single...

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DESIGN & ANALYSIS OF SINGLE STAGE INDUSTRIAL

HELICAL GEARBOX CASING

Rahul Yashwant Banekar1, Prof.A.C.Mattikali2 1M.Tech.,Mechanical Engg. Dept., MMEC, Belagavi

2 Assistant Prof. Mechanical Engg. Dept. MMEC, Belagavi

Abstract— This paper contains the study of structural analysis of a single stage industrial Helical

gearbox casing using Finite Element Analysis (FEA) Method. Gearbox casing is plays an important

role in power transmission system. Thus the strength, weight, manufacturability and cost of gearbox

casing are an important factor is to be taken while designing. The 3D model is prepared by using

Pro-E creo2.0 pre-processing is prepared by using Hypermesh 11.0 while FEM is solved by using

Ansys 14.5 solver. It was statically analyzed using simulation software Altair Hypermesh and Ansys.

Static analysis is to find out the total amount of stresses and displacement of gearbox casing and End

cover.

Keywords—Gearbox casing, FEA, Optimization, Static analysis, Pro-E creo, Hypermesh, Ansys,

I. INTRODUCTION

The casing encloses different sets of helical gears, bearings to support the shafts. This Gear

box is used in all industries to reduce speed and increase torque. Casing is a part of gear box, it

provides support to shaft, bearing and hence the gear loading. It is a fabricated from Fabsteel IS2062

material. This material selection is based on the criteria of strength, rigidity, cost etc. For casting,

there are many factors to be considered for better result such as material properties, mechanical

properties, chemical composition, fluidity, boundary clearance, thermal properties, etc. to fulfill all

this criteria. The Objective of this project to optimize and find out the effective design of gearbox

with minimum weight by reducing raw material cost without affecting function and investigate effect

of load on stress, displacement in Gear box through finite element analysis.

Technical Specification- H1-80

H- Helical, 1- Stages, 80-Input to Output center distance.

Table.1.0 Input Data

II. DESIGN CALCULATION

The force on each bearing tabulated as follows, Table 2.0 Bearing forces

Clockwise Rotation

Fx(N) Fy(N) Fz(N) Angle Fr(N)

Shaft 1 Bearing 1 125 0 -382 -71.93 402

Bearing 2 161 -143 -344 -64.96 380

Shaft 2 Bearing 1 -274 143 366 129.79 457

Bearing 2 -12 0 373 91.81 373

Power 1.5Kw

Input Speed 1500 rpm

Output speed 293.54 rpm

Ratio 5.11:1

International Journal of Recent Trends in Engineering & Research (IJRTER) Volume 02, Issue 10; October - 2016 [ISSN: 2455-1457]


III. METHODOLOGY

The problem under consideration will be modeled through three approaches:

A. CAD Modeling

B. Preprocessor using hypermesh

i. Meshing

ii. Boundary Condition and load condition

C. Postprocessor using Ansys

i. Stress plot result

ii. Deformation plot result

3.1 Cad Modeling

3D model is prepared by using Pro-E Creo2.0. The CAD Model of gearbox casing

specification is Length-292mm, Width-120mm, Height- 180mm and thickness 5mm.

Figure 1.0 CAD Model

3.2 Preprocessor

3.2.1 Meshing

3D solid model in STEP file format is imported in Hypermesh. Mesh model is

prepared by using Hypermesh11.0. 2D. tria meshing is carried out on all the inner and outer surfaces

of the geometry, quads splits to trias and then converted to tetras. A 4-node Linear Tetra 3D solid

elements are used to model of Gearbox and End covers. The element size selected for Casing and

End covers mesh is 5 mm



Figure 2.0 Meshing model of gearboxcasing

3.2.2 Boundary condition

The Horizontal foot mounted Gearbox bottom casing is fix connected to the foundation via

six bolting attachments as shown in fig. 3.0. Resting face is constrained in all degree of freedom.

Boundary conditions can be applied to geometry, including faces, edges, curves, points, mesh points,

vertices, nodes, elements or the entire model. There are various types of load applicable over gearbox

casing. The Static load of transmission gear and drive shaft act on bearing hole it divide into two

parts namely, Radial force and axial force on each gear have to analysis. These loads are applied to

find the actual effect of stress and deformation on gearbox.

Figure 3.0 Constrained Conditions

Bearing Radial forces on the housing are applied on the mass element which is spread

over 120° (60° on each side of bearing resultant force direction) on housing through rigid element.

Bearing Radial Forces on the components in X and Z Direction are applied on the Mass element



which is connected to Component through Rigid Element at 120° of resultant angle.

Figure 4.0 Loading Conditions

3.1 Postprocessor

The static analysis is performed in hypermesh/Ansys and through applying boundary conditions

and forces which are calculated using kisssoft/Kisssys or analytical calculation. Static analysis of

the gearbox casing to find out the total amount of stresses and deformation of and deformation of

structural component

3.1.1 Stress plot result

(a) Von-mises stress plot

Figure 5.0 Von Mises stress plot



(b) Bottom Casing stress plot

Figure 6.0 Bottom Casing stress plot

(c) Top casing stress plot

Figure 7.0 Top casing stress plot



3.1.2 Deformation plot

(a) Overall Displacement

Figure 8.0 Overall Displacement plot

(a) Diplacement plot along ‘x’ Direction

Figure 9.0 Displacement plot along ‘X’ Direction

(b) Diplacement plot along ‘Y’ Direction

Figure 10.0 Diplacement plot along ‘Y’Direction



(c) Diplacement plot along ‘Z’ Direction

Figure 11.0 Diplacement plot along ‘Z’Direction

3.2 Results Table 3.0 Stress plot result

SL

No.

Part Material Allowable

Stress (MPa)

Maximum

Stress (MPa)

1. Assembly Casing FabSteel 250 3.82

2. Top Casing FabSteel 250 3.82

3. Bottom Casing FabSteel 250 2.003

Table 4.0 Displacement Plot result

VI. CONCLUSION

Static analysis of the gearbox casing has done using commercial software hypermesh. Analysis is

to find out the total amount of stresses and deformation of structural components. The gearbox

casing and Cather cover is manufactured from Fab steel (IS: 2062) material. The Max.Von Mises

stress found is 3.82 MPa. Also the maximum displacement of the casing it is found 9.0 micron.

Although the acceptable limits of Stress & displacements are very higher than actually induced

on casing. So still there is more safety factor is there, but we have manufacturing constraint that

we cannot optimize beyond this limit of 5 mm wall thickness. The reason is that, during stress

reliving cycle, plate sizes below 5 mm get Distortions, which results in bending of gearbox

casing plates.

SL

No.

Description Material Max.Displacement

‘mm’

1. Overall Displacement FabSteel 0.0091

2. Displacement along ‘x’

Direction

FabSteel 0.0029

3. Displacement along ‘Y’

Direction

FabSteel 0.0065

4. Displacement along ‘Z’

Direction

FabSteel 0.00325



Table 4.0 Comparison

SL Description Material Size

mm

Allowable

stress(Mpa)

Max.

stress(Mpa)

Displacemnt

In mm

Weight

kg

1. Traditional

Design

FG260 L=347

W=308

h=203

260 5.687 0.0027 32.96

2. Optimum

Design

FabSteel L=292

W=190

h=120

250 3.820 0.0090 26.33

From above comparison table it can clearly conclude that the optimum design is better than the

traditional one in weight factor.

AKNOWLEDGEMENT

It gives me great pleasure to present this paper on “Design and Analysis of single stage

Industrial helical gearbox casing”. I am very much obliged to contributors for developing and

maintaining the IJRTER International Journals. I will fail in my duty if I won't acknowledge a great

sense of gratitude to entire staff members in Mechanical Department of MMEC, Belagavi, for their

co-operation. Last but not least, I am also thankful to my parents & friends who directly and

indirectly helped in developing this paper.

REFERENCES 1. Shrenik M. Patil , Prof. S. M. Pise Modal And Stress Analysis Of Differential Gearbox Casing With Optimization

Nov-Dec 2013 At Int. Journal Of Engineering Research And Application.

2. Prof. Dr. M. A. Nasser, Prof. Dr. F. R. Gomaa, Structural Modifications of 1K62 Engine Lathe Gearbox

Casing.Volume-3, issue-2, February 2015.

3. Vasim Bashir Maner, M. M. Mirza, ShrikantPawar Design Analysis And Optimization For Foot Casing Of Gearbox

3rd Irf International Conference, 10th May-2014, Goa, India.

4. DrInż. ZbigniewZdziennicki, DrInż. AndrzejMaciejczyk Design Basic Of Industrial Gear Boxes

5. J.K. Gupta R.S. Khurmi, A Textbook Of Machine Design Eurasia Publishing House, 2005, Page 1066-1079.

6. AGMA 2101 D04, Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth.

ANSI/AGMA 2101-D04, Reaffirmed January 2010.

7. K. mahadevan, K. Balaveera Reddy, Design Data Hand book, Third edition 1987, CBS Publishers & Distributers

PVT. LTD. Page 168-171

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