Stress and mesh stiffness evaluation of bimaterial spur gears

Abstract

Lightweight spur gears have been a trending topic in aerospace and automotive applications recently. Traditionally, weight reduction could be ensured by using gear body with holes or thin rim design which result in to fluctuate mesh stiffness or it may increase stress and deformation levels. Indeed, high stresses occur in only contact and root region of gear tooth during the meshing process, so other regions are subjected to low stress. Based upon this point; various materials with low density and adequate strength could be used in low stress region while gear steel remains for high stress region. In this study, two different lightweight materials (Aluminum alloy and Carbon fiber reinforced polymer) were used for low stress region. The effect of these materials was investigated in view of stiffness and root stress for the same gear design parameters. Unidirectional CFRP laminas were used in a symmetric lay up to ensure quasi-isotropic laminate properties. Finite element analyses were conducted to obtain root stress and then total deformation of the tooth for stiffness calculation. Interface properties of ring and core regions were assumed as pure bonded. Meshing load was applied on the highest point single tooth contact (HPSTC) line. Weight reduction ratios were also compared. According to results, the steel/composite design is superior to steel/aluminum hybrid design in view of stress, stiffness and weight.