Publication: Finite element analysis and surface characterization of spur gear
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Date
2024-07-11
Authors
Deniswaran a/l Sivaraman
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Abstract
Gears are fundamental components in mechanical systems, where any malfunction can severely affect overall performance. Effective lubrication methods are essential for reducing friction, wear, and potential damage to gear teeth, thereby preventing catastrophic failures. This study focuses on the finite element analysis (FEA) and surface characterization of spur gears to understand their stress distribution, deformation, and failure mechanisms, with an aim to enhance gear performance and longevity through optimized design and effective lubrication strategies. The primary objectives of this research are to investigate the stress distribution on the gear tooth surface using FEA and to perform a failure analysis on worn gears through surface characterization techniques such as Scanning Electron Microscopy (SEM) and Laser Scanning Microscope (LSM). The gear model is designed using SOLIDWORKS, and ANSYS software is employed for the simulation. The resulting contact stress data from FEA is compared with experimental data to validate the simulations. Results indicate that stress concentrations are predominantly located at the gear tooth root and tip, highlighting critical areas for potential failure. Surface characterization reveals significant wear patterns and roughness, underscoring the importance of proper lubrication in maintaining gear integrity. The gear lubricated with palm oil shows the lowest surface wear indicated by low roughness and less surface damage. By integrating FEA with detailed surface analysis, the study provides comprehensive insights into the mechanical behavior and surface integrity of spur gears, essential for their optimal design and improved operational efficiency.