Gear Bending Stress Analysis of Automatic Transmissions with Different Fillet Curves

Gear bending strength is a core indicator to indicate reliability and operation performances of automotive transmissions. Fillet curve design of dedendum of gear teeth can improve their bending stress and complex tooth contact perfor-mance. Geometrical parameters of gears are considered important for the varia-tion of stresses in the design of gears. Bending stress analysis has been a key area of research to minimize failure and optimize design. This work presents a finite element (FE)-based analysis method of gear bending stress, which can be used for multiple spatial meshing gear teeth simultaneously. Three-dimensional (3D) models of helical gear with double and single circular fillet curves are estab-lished by using Pro/ENGINEER. By changing of meshing positions of gears, tooth contact analysis results along their paths of contact are obtained. Since FE-based tooth contact analysis are performed based on 3D models, the results of bending stress are reliable and authoritative. It is proved that bending stress of the gear with double circular fillet curves is 1.3~1.5 times as that of the gear with single circular fillet curves, which means that gear with single circular fillet curves has better loading capacity than gear with double circular fillet curves. The study will provide a good method for studying gear bending stress to improve gear de-sign of automotive transmissions.

Keywords:

Involute gears, Bending stress Finite element analysis, Fillet curves,

PDF

___

Kulkarni M, Shim T, Zhang Y. Shift dynamics and control of dual-clutch transmissions. Mech Mach Theory. 2007;42(2):168-182.
Hu YH, Li G, Zhu WD, Cui JK. An elastic transmission error compensation method for rotary vector speed reducers based on error sensitivity analysis. Appl Sci. 2020;10(2):481.
Yan J, Li G, Liu K. Development trend of wind power technology. Int J Adv Eng Res Sci. 2020;7(6):124-132.
Srivastava N, Haque I. Transient dynamics of metal V-belt CVT: Effects of band pack slip and friction characteristic. Mech Mach Theory. 2008;43(4):459–479.
Li G. Design and modeling of an impulse continuously variable transmission with a rotational swashplate. Int J Auto Sci Tech. 2020;4(4):307-313.
Xu M, Zhang X, Hu G, Li G. The structure design and flow field simulation of a fire water monitor driven by worm gear with bevel gear. Mach Tool & Hydra. 2016;6:57-61.
Gu KL, Wang ZH, Li G, Liu XR. Optimization of geometric parameters of the straight conjugate internal gear pump based on GA. Elec Sci Tech, 2017;30(6):39-42.
Zhang XL, Wang ZH, Li G. Research on virtual hobbing simulation and study of tooth surface accuracy of involute helical gears. Appl Mech Mater. 2012;155:601-605.
Li G, Wang ZH, Zhu WD, Kubo A. A function-oriented active form-grinding method for cylindrical gears based on error sensitivity. Int J Adv Manuf Tech. 2017;92(5-8):3019-3031.
Wang ZH, Zhu WM, Li G, Geng Z. Optimization of contact line for form-grinding modified helical gears based on neural network. China Mech Eng. 2014;25(12):1665-1671.
Li G. An active forming grinding method for cylindrical involute gears based on a second-order transmission error model. SCIREA J Mech Eng. 2019;2(1):1-14.
Li G, Zhu WD. An active ease-off topography modification approach for hypoid pinions based on a modified error sensitivity analysis method. ASME J Mech Des. 2019;141(9):093302.
Li G, Wang ZH, Kubo A. Error-sensitivity analysis for hypoid gears using a real tooth surface contact model. Proc Instn Mech Eng, Part C: J Mech Eng Sci. 2017;231(3):507-521.
Zhang WX, Wang ZH, Liu XR, Li G, Wan PL, Wang W. Research on optimization of temperature measuring point and thermal error prediction method of CNC machine tools. J Shaanxi University of Tech (Na Sci Ed). 2017; 33(3):18-24.
Wang ZH, Cao H, Li G, Liu XR. Compensation of the radial error of measuring head based on forming grinding machine. J Mech Trans. 2017;41(3):143-146.
Wang ZH, Song XM, He WM, Li G, Zhu WM, Geng Z. Tooth surface model construction and error evaluation for tooth-trace modification of helical gear by form grinding. China Mech Eng. 2015;26(21):2841-2847.
Li G, Wang ZH, Kubo A. Tooth contact analysis of spiral bevel gears based on digital real tooth surfaces. Chin J Mech Eng. 2014;50(15):1-11.
Wang ZH, Wang J, Ma PC, Li G. Dynamic transmission error analysis of spiral bevel gears with actual tooth surfaces. J Vib Shock. 2014;33(15):138-143.
Wang ZH, Wang J, Wang QL, Li G. Transmission error of spiral bevel gear based on finite element method. J Vib Shock. 2014;33(14):165-170.
Li G, Wang ZH, Kubo A. The modeling approach of digital real tooth surfaces of hypoid gears based on non-geometric-feature segmentation and interpolation algorithm. Int J Prec Eng Manuf. 2016;17(3):281-292.
Li G, Zhu WD. Design and power loss evaluation of a noncircular gear pair for an infinitely variable transmission. Mech Mach Theory. 2021;156:104137.
van Berkel K, Hofman T, Vroemen B, Steinbuch M. Optimal con-trol of a mechanical hybrid powertrain. IEEE Trans Vehic Tech. 2012;61(2):485-497.
Huang DQ, Wang ZH, Li G, Zhu WD. Conjugate approach for hypoid gears frictional loss comparison between different rough-ness patterns under mixed elastohydrodynamic lubrication regime. Tribo Int. 2019;140:105884.
Li G, Wang ZH, Zhu WD. Prediction of surface wear of involute gears based on a modified fractal method. ASME J Tribo. 2019;141(3):031603.
Wu J, Wang ZH, Li G. Study on crack propagation characteristics and remaining life of helical gear. J Mech Trans. 2014;38(12):1-4.
Wan GQ, Huang Y, Zhang FJ, Li G. Integrated powertrain control for gear shifting. Appl Mech Mater. 2012;148:725-730.
Li G, Wang ZH, Geng Z, Zhu WM. Modeling approach of digital real tooth surfaces of hypoid gears based on non-geometric-feature segmentation and interpolation algorithm. Chin J Mech Eng. 2015;51(7):77-84.
Li G, Geng Z. Tooth contact analysis of herringbone rack gears of an impulse continuously variable transmission. Int J Auto Sci Tech. 2021;5(1):52-57.
Wang ZH, Yuan KK, Li G. Optimization identification for dynamic characteristics parameters of sliding joints based on response surface methodology. China Mech Eng. 2016;27(5):622-626.
Hu YH, Li G, Hu AM. Iterative optimization of orbital dynamics based on model prediction. Front Arti Intel App. 2019;320:76-86.

International Journal of Automotive Science and Technology-Cover

Yayın Aralığı: Yılda 4 Sayı
Başlangıç: 2016
Yayıncı: Otomotiv Mühendisleri Derneği

Arşiv