Machine Design and CAD Lab 2016,

Semester 1- 2016/2017,
UNITEN

GEAR DESIGN
STRUCTURAL ANALYSIS

Mohd Syafiq Bin Mohd Fauzi (ME095818), Palamuthan Pandian (ME094212),

Cheh Song Ding (ME094638), Yap Chee Yeong (ME095611)
Department of Mechanical Engineering
College of Engineering, UNITEN
Putrajaya, Malaysia

Abstract— For this project, a gear was designed, based on the factor. Decision was then made to change some dimensions to
common gears which are used in most of mechanical based decrease the maximum shear stress at the teeth which holds the
machineries. The safety factor of the gear component is considered force applied in contact to the gear. The optimized diameter
carefully by choosing a suitable material. In this project,
provides a maximum shear stress of 231.71 MPa and safety
software’s such as PTC Creo Parametric 3.0 is used for designing,
factor of 1.7.
simulation for force and stress, and also analyzing the gear. All the
results obtained from the simulation is then discussed in detail.

II. Mechanical Part & Assembly

I. Introduction Detail Design
A gear also known as ‘gear wheel’ is a rotating machine part
A. Isometric (3D) Drawing and multiview Projection with
having cut teeth which mesh with another toothed part in order Dimensions .
to transmit torque [1]. Gears are mainly used in tons of
mechanical devices. They do several important jobs, but most
important they provide a gear reduction in motorized
equipment. Another thing gears do is adjusting the direction of
rotation. For instance, the differential between the rear wheels
and of the car, the power is transmitted by a shaft that runs down
the center of the car and the differential has to turn that power
90 degrees to apply it to the wheels [2].

In this project, a simple gear is designed referring to the

common gears that are already produced, in aspects of shape,
style, material and safety factor. This gear is made up of
aluminium alloy (Al -14). We have also set our design target
which is for the gear to have a safety design factor of 1.7.

In simulation process, it is discovered that the part which

experienced the highest maximum shear stress is at the teeth of
the gear. This is mainly because as it is the main part in
supporting the force applied on the component. The allowable
stress for aluminium alloy with a factor of safety of 1.7 is
Figure 1: 3D Isometric of Gear (1.0)
243.543 MPa. With the usage of initial dimensions of the teeth,
it was found that the teeth undergo a maximum shear stress of
262.98 MPa which in consequence fail to meet the design
Machine Design and CAD Lab 2016,
Semester 1- 2016/2017,
UNITEN
III. Mechanical Part Standard
Design Study
A. Design for Manufacturability.

Design Consideration
The accuracy of the output of a gear depends on the accuracy
of its design and manufacturing. The correct manufacturing of
a gear requires a number of prerequisite calculations and design
considerations . The design considerations taken into account
before manufacturing of gears are :

1. Strength of the gear in order to avoid failure at starting

torques or under dynamic loading during running
conditions.
2. Gear teeth must have good wear characteristics.
3. Selection of material combination.
4. Proper alignment and compactness of drive.
5. Provision of adequate and proper lubrication
Figure 2: 3D Isometric of Gear (2.0) arrangement.

Shown above are the 3D isometric drawings of the gear with an

applied force of 3000N (3KN) and a fixed constraint at the shaft B. Material Selection
hole.
The gear material should have the following properties;
i. High tensile strength to prevent failure against static
loads.
ii. high endurance strength to withstand dynamic loads.
iii. low coefficient of friction.
iv. good manufacturability.

For this project aluminium alloy is used because of its

high range of tensile strength.

1. Component: Gear

Material: Aluminium Alloy (AL-2014)

Properties of Materials Descriptions

Drawing 1: Multiview Projection of the Gear Density 2.80 g/cm3

Yield Strength 190 to 480 MPa

Young’s Modulus 73 GPa
Compression Strength 65 MPa

Table 1: Properties of Material

Machine Design and CAD Lab 2016,
Semester 1- 2016/2017,
UNITEN
D. Results of Desgined Gear Simulation.
C. Force and Constraints

Figure 5: Designed Gear Simulation

Figure 3: Force applied on Gear
The highest value of deformed maximum shear stress
experienced by the gear is 262.976 MPa and the lowest value
of shear stress experienced is 0.00089 MPa. This is when we
used the height of gear of 100 mm, thickness of gear of 80 mm
and distance between teeth (gap analysis) of 5 mm.

IV. Mechanical Part Sensitivity

Design Study
A. Global Sensitivity Studies for gear

Figure 4: Constraint Applied on Gear

The force was applied at the teeth of the gears and the constraint
was fixed at the shaft hole respectively. The force applied at the
teeth is 3000 N.

Graph 1: Before Optimization

Machine Design and CAD Lab 2016,
Semester 1- 2016/2017,
UNITEN

Graph 1 shows the maximum von misses stress which is set to

SI Unit of MPa, which uses the initial dimensions (radius of
gear was set to 100 mm, thickness of gear is 80 mm and distance
between the teeth is of 5mm). These dimensions give a
maximum stress of 262.98 MPa. This stress clearly fails our
design target.

Graph 4: Gear Sensitivity Width Analysis

Graph 4 shows that the width of the gear was changed to a range
of 70 mm to 90 mm to achieve the design target and also the
ideal stress.

V. Mechanical Part Optimization

Design Study
Graph 2: Gear Sensitivity Height Analysis
Based on the Global Sensitivity Studies for each
component, it can be seen that gear has the highest value of
Graph 2 shows that the height of the gear was changed to a
Maximum Shear Stress of 262.976 MPa by referring to Graph
range of 40 mm to 200 mm to achieve the design target and also
1. Hence, optimization is done on gear by increasing the
the ideal stress.
diameter from 100 mm to 200mm, in order to reduce the
maximum shear stress, occur on the part, so that safety factor of
1.7 can be achieved.

A. Result Optimization Studies on Gear

Graph 3: Gear Sensitivity Teeth Gap Analysis

Graph 3 shows that the distance between the teeth of the gear
was changed to a range of 6 mm to 8 mm to achieve the design
target and also the ideal maximum stress.

Figure 6: Force and constraint applied on optimized gear

Machine Design and CAD Lab 2016,
Semester 1- 2016/2017,
UNITEN

Graph 5: Maximum von Misses Stress versus Optimization

Pass

VI. Conclusion
Drawing 2: Optimized Gear The project is initially designed and then it is brought to
Standard Design by using PTC Creo Simulation. The Maximum
Shear Stress and Maximum von Misses Stress is studied for
gear and is found to have experienced the highest Shear Stress
value of 262.976 MPa. Hence the component is brought to
further Optimization Design Study. The original dimensions
were altered to get an ideal shear stress value of 231.078 MPa.
To conclude, the goal of the project is achieved.

Acknowledgment
We would like to show our gratitude to the Mr. Iszmir Nazmi
Bin Ismail, our course instructor for sharing his pearls of
wisdom with us during the course of this project. Many thanks
to those who had provided insight and expertise that greatly
assisted the project, although any errors are our own and should
not tarnish the reputations of these esteemed person.

Figure 7: Optimized Fringe Plot of Gear References

The optimized gear experienced the maximum shear stress of

[1] Provoshi Jack,P [2013]. Gear Introduction: http://
231.708 MPa. mechanicalmania.blogspot.my/2011/07/gear-introduction-html.
[2] Elizabeth [2013]. How Gears Work:
http://apps.elizabethtown.kctcs.edu/members/jnail/BRX-Gears.htm