Optimization of Model and Structural Analysis Hypoid Gear

The purpose of this work is to analyze structural behaviour of differential hypoid gear. For the studying of the structural analysis of the gear is made up of the different composite materials & as well as alloy materials compared with conventional metallic materials. As, composite materials provide enough strength and emerged as a good alternative for replacing metallic gears which is Ni-Cr steel. The alloy materials considered here is Aluminium alloy, Grey cast iron, and the composite material is Epoxy E-Glass unidirectional and compare with existing gear material Ni-Cr steel. This work makes an attempt to replace the metallic gears of Ni-Cr steel with alloy & composite materials based on static structural analysis results. For the analysis purpose the solid model is created by using CATIAV5R20 design software and ANSYS 17.1 is used to determine the Total deformation, Von-Mises stress and the equivalent elastic strain for the different selected materials at three different speeds.


INTRODUCTION
Now a day's gears are used in many applications for transmission of motion from one shaft to another shaft. The gears drives are positives which are transmit exact velocity ratio, the gear drives are transmit motion when two shafts distances are less than compared to the belt, chains, rope drives. The gear drive is used when the shaft having long centre distances this time some idler gears are using between driver and driven gears f or transmission of motion from one to another shaft. Thus providing the idler gears the co st also in creased and maintained cast also high than compared to the other power transmission drives like belt, rop es and chain drives, for this reason the gear drives not recommend for transmission of motion from large cen tre d istan ces from driving shaft to the driven shaft. Now a day's gears are various types are available in the market, based on the type of application, purpose and working condition the gear materials is selected, because th e selection o f the material is most important for manufacturing of the any component, because the tensile strength, young's modules, corrosion resistance, efficiency and life of the material etc. can be depended into the selection of the material.
This work makes an attempt to replace the conventional metallic gears of Ni-Cr steel gear material with the alloy & composite materials having application for high power transmission system & reducing of th e stress same as a gearbox were in automobile industries. For this purpose 3-D solid model o f th e d ifferential hypoid gear made in CATIA V5R20 design software and ANSYS 17.1 finite element method analysis software were used to carry out the static analysis in order to identify the behaviour of the conventional Ni-Cr steel gear material and identified replacements of different alloy & composite materials under the different loading criteria's. Then the simulation of the results determines the total deformation, Equivalent Vo n-Misses Stress, and Equivalent Strain of the different selected materials at three different rpms.

FEM ANALYSIS OF THE GEAR
In this project numerical method of the FEM based static structural analysis carried out by using ANSYS 1 7.1 analysis software. FEM (Finite element analysis) a computer-based analysis technique is used of the studying the behaviour of structures under the applied blundered conditions. The ANSYS 17.1 analysis software determine results like the total deformation, Equivalent Von -misses Stress, and Equivalent elastic strain under the applied boundary conditions. The 3D model for numerical analysis developed in CATIA V5R20 design and these models have been imported in ANSYS as IGES file format for further.

TORQUE CONSIDERATION
For the analysis purpose of the differential hypoid gear the applied boundary conditions are friction less supports, that means all gears are rotated in applied rpms and three different rpms were uses for conducting of the static structural analysis. Based on the selection of the different materials and applied boundary conditions the results are generated. The various torques and rpms for the analysis is mention in the below table .

STATIC STRUCTURAL ANALYSIS
This analysis, which is numerical method of the ANSYS software analysis, the static structural analysis wh ich is a system based analysis, that means, resulting the static structural analysis is generated by computer based on the selection of various different materials an applied boundary conditions the computer solve the results with the help of preloaded formulas and theorems the results will be generated. The static structural analysis is mainly conducted to find the selected material for gear manufacture can withstand or not for the applied lo ads and generation stress, temperatures etc. during motion. To finding the best material for the manufacturing of the differential hypoid gear is mandatory.
In this work, the FEA tool were used to identify the structural behaviour of various alloy materials and composite material under certain boundary conditions there by determining total deformation, equivalent Vo nmises stress and maximum strain for each alloy material and as well as composite material then the comparison was done with previous existing metallic gear material which is Ni-Cr steel. In this research work FEM structural analysis simulation results were shown the behaviour of Ni-Cr steel, Aluminium Alloy, Grey Cast Iron alloy materials and Epoxy E-Glass_UD composite material at the applied boundary conditions th e results of the static structural analysis were shown below as:   reduced and the aluminium alloy has low density, based on low density the overall weight of the gearbox was reduced. 4. By decreasing of the weight of the gearbox the efficiency of the gear will be increased.

5.
After the aluminium alloy material the next suitable material is Epoxy E-glass unidirectional composite material is suitable for manufacturing of the hypoid gear.

FUTURE SCOPE OF THE WORK
In the present investigation of static analysis of hypoid gear is analyzed by single composite material in as a future work, the number of composites and some advanced alloy, nano materials with different rpms was also tested for manufacturing of the hypoid gear to overcome of the gear teeth failure by applying of the excessive loads.