Developing an analytical approach and modeling procedure to evaluate stress distribution and quenching process under velocity and moment would provide a useful tool to improve spur gear design with high efficiency and low cost. Based on the theories of gear engagement, contact analysis and friction, a three dimensional finite element model of the spur gear system was established to investigate stress distribution and analyze the advantage of quenching process. A full-scale deformable-body model and a simplified discrete model were both shown to be accurate through extensive comparisons to the theoretical database generated in this study. The major work is summarized as follows.
Applying Finite Element Method, contact stress analysis of meshing spur gears was conducted.
Applying the relation equation in Pro/Engineer, an accurate three dimensional spur gear model was developed. This model can be used to analyze many similar spur gears for design optimization.
Three dimensional finite element models of spur gear system were established to investigate stress distributions over operating speeds with consideration of lubrication conditions. The three-dimensional FEA program developed can be a useful tool in investigating design parameters for spur gears.
A theoretical finite element model of spur gear system was developed. The research result shows that the theoretical methods presented in this thesis have good simulation accuracy. This method could also be applied to many other engineering problems.
Finite Element simulation of spur gear was developed and used to predict distributions of stress and other material properties. Thermo-elastic-plastic constitutive equation coupled with the mechanical strain, thermal strain, phase transformation strain, and transformation induced plasticity is described in detail. The quenching result in the simulation proved the theory and ensured product quality.