In this study, the effect of rim thickness of hybrid gears on the root stress, joint stress, tooth stiffness, natural frequency, and dynamic behavior are examined numerically. Hybrid gears consist of two materials, which are steel for the teeth-rim and hub regions of gear, carbon fiber reinforced plastic (CFRP) for the web region. Adhesive bonding is assumed for the joining of steel and composite materials. FE method is used to evaluate tooth root stress, joint stress, tooth deformation, and the natural frequency of hybrid gears. The adhesive is defined by cohesive zone modeling (CZM). Moreover, 2-DOF dynamic analyses are implemented to obtain dynamic factors and static transmission error. According to results, hybrid gears have substantial potential to reduce the mass of gear transmission systems with no adverse effect on root stress and dynamic factor if the design parameters are appropriately selected. Besides, rim thickness is found as a critical parameter for the hybrid gears since when its value changes from 0.5xm to 3xm, the root stress decreases 10% while the tooth stiffness and torque capacity increase 20% and 65%, respectively.
International Energy Outlook Report. Washington, DC: U.S. Energy Information Administration, 2013.
2.
YuceCKarpatFYavuzN, et al. A case study: designing for sustainability and reliability in an automotive seat structure. Sustainability (Switzerland)2014; 6: 4608–4631.
3.
YilmazTGTüfekçiMKarpatF.A study of lightweight door hinges of commercial vehicles using aluminum instead of steel for sustainable transportation. Sustainability (Switzerland)2017; 9: 1661.
4.
LeeSKimBLeeH-J, et al. Warm forging of an aluminium alloy for the differential case in an automobile transmission. Proc IMechE, Part D: J Automobile Engineering2016; 230: 1131–1139.
5.
WuPWangBLinJ, et al. Investigation on metal flow and forming load of bi-metal gear hot forging process. Int J Adv Manuf Technol2017; 88: 2835–2847.
6.
LisleTJShawBAFrazerRC.External spur gear root bending stress: a comparison of ISO 6336:2006, AGMA 2101-D04, ANSYS finite element analysis and strain gauge techniques. Mech Mach Theory2017; 111: 1–9.
7.
ChoSKKimHJChangSH.The application of polymer composites to the table-top machine tool components for higher stiffness and reduced weight. Compos Struct2011; 93: 492–501.
8.
KimJHChangSH.Design of μ-CNC machining centre with carbon/epoxy composite-aluminium hybrid structures containing friction layers for high damping capacity. Compos Struct2010; 92: 2128–2136.
9.
ChoDHLeeDGChoiJH.Manufacture of one-piece automotive drive shafts with aluminum and composite materials. Compos Struct1997; 38: 309–319.
10.
BaeJHJungKCYooSH, et al. Design and fabrication of a metal-composite hybrid wheel with a friction damping layer for enhancement of ride comfort. Compos Struct2015; 133: 576–584.
11.
HandschuhRRobertsGDSinnamonR, et al. Hybrid gear preliminary results—application of composites to dynamic mechanical components. In: 68th American Helicopter Society (AHS) Annual forum and Technology Display, Fort Worth, Texas, 2012, NASA/TM—2012-217630, pp. 1–18.
12.
HandschuhRFLabergeKEDelucaS, et al. Vibration and operational characteristics of a composite-steel (hybrid) gear—NASA/TM—2014-216646, 2014.
13.
LaBergeKEBerkebileSPHandschuhRF, et al. Hybrid gear performance under loss-of-lubrication conditions. In: American Helicopter Society International 73rd Annual Forum & Technology Display, Fort Worth, Texas, USA, 9-11 May 2017, pp. 2250–2256. Fairfax: AHS.
14.
CateraPGGagliardiFMundoD, et al. Multi-scale modeling of triaxial braided composites for FE-based modal analysis of hybrid metal-composite gears. Compos Struct2017; 182: 116–123.
15.
CateraPGMundoDTrevisoA, et al. On the design and simulation of hybrid metal-composite gears. Appl Compos Mater2019; 26: 817–833.
16.
ContarteseNCateraPGMundoD.Static mesh stiffness decomposition in hybrid metal-composite spur gears. In: TUhl (ed.) Advances in mechanism and machine science. Berlin: Springer International Publishing, 2019, pp. 977–985.
17.
CateraPGMundoDGagliardiF, et al. A comparative analysis of adhesive bonding and interference fitting as joining technologies for hybrid metal—composite gear manufacturing. Int J Interact Des Manuf2020; 14: 535–550.
18.
KarpatFYılmazTGDoganO, et al. Stress and mesh stiffness evaluation of bimaterial spur gears. In: ASME International Mechanical Engineering Congress and Exposition, Proceedings IMECE), Salt Lake City, Utah, USA, 11-14 November 2019. New York: ASME. DOI: 10.1115/IMECE2019-11554.
19.
GaunttSMCampbellRL. Characterization of a hybrid (steel-composite) gear with various composite materials and layups. In: American Institute of Aeronautics and Astronautics Scitech 2019 Forum, San Diego, USA, 7-11 January 2019. Reston: AIAA. DOI: 10.2514/6.2019-0146.
20.
GaunttSCampbellRMcIntyreS. Design optimization of a hybrid spur gear. In: Vertical Flight Society’s 75th Annual Forum and Technology Display, Philadelphia, USA, 13-16 May 2019. Fairfax: AHS.
21.
KimHKimCKimS, et al. Novel steel and aramid/phenol composite gear for a transmission with optimum design and FEM vibration analysis. Intj Automot Technol2019; 20: 749–754.
22.
WenQDuQZhaiX.A new analytical model to calculate the maximum tooth root stress and critical section location of spur gear. Mech Mach Theory2018; 128: 275–286.
23.
ZouTShakerMAngelesJ, et al. An innovative tooth root profile for spur gears and its effect on service life. Meccanica2017; 52: 1825–1841.
24.
DIN 3990-3:1987-12. Calculation of load capacity of cylindrical gears; calculation of tooth strength.
25.
CavdarKKarpatFBabalikFC.Computer aided analysis of bending strength of involute spur gears with asymmetric profile. J Mech Des2005; 127: 477–484.
26.
MoSMaSJinG. Research on composite bending stress of asymmetric gear in consideration of friction. Proc IMechE, Part C: J Mechanical Engineering Science2018; 233: 2939–2955.
27.
YilmazTGDogˇanOYüceC, et al. Improvement of loading capacity of internal spur gear with using asymmetric trochoid profile. In: ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE), Tampa, Florida, USA, 3-9 November 2017. New York: ASME. DOI: 10.1115/IMECE2017-71009.
28.
PolitisDJPolitisNJLinJ, et al. An analysis of the tooth stress distribution of forged bi-metallic gears. Proc IMechE, Part C: J Mechanical Engineering Science2018; 232: 124–139.
29.
LitvinFFuentesA.Gear geometry and applied theory. 2nd ed.Cambridge: Cambridge University Press, 2004.
30.
FetvaciCImrakE.Mathematical model of a spur gear with asymmetric involute teeth and its cutting simulation. Mech Based Des Struct Mach2008; 36: 34–46.
31.
ChamisCC.Mechanics of composite materials: past, present, and future, NASA/TM-1984-100793, 1984.
32.
RibeiroTEACampilhoRDSGda SilvaLFM, et al. Damage analysis of composite-aluminium adhesively-bonded single-lap joints. Compos Struct2016; 136: 25–33.
33.
ShokrianMDShelesh-NezhadKSoudmandBH.3D FE analysis of tensile behavior for co-PP/SGF composite by considering interfacial debonding using CZM. J Reinf Plast Compos2016; 35: 365–374.
34.
LongHLordAAGethinDT, et al. Operating temperatures of oil-lubricated medium-speed gears: numerical models and experimental results. Proc IMechE, Part G: J Aerospace Engineering2003; 217: 87–106.
35.
LabergeKEHandschuhRFRobertsG, et al. Performance investigation of a full-scale hybrid composite bull gear. In: American Helicopter Society International 72nd Annual Forum & Technology Display, West Palm Beach, Floria, USA, 17-19 May 2016. Fairfax: AHS.
36.
KarpatFDoganOEkwaro-OsireS, et al. A novel method for calculation gear tooth stiffness for dynamic analysis of spur gears with asymmetric teeth. In: ASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE), 2014, pp. 1–8.
37.
KarpatFDoganOYuceC, et al. An improved numerical method for the mesh stiffness calculation of spur gears with asymmetric teeth on dynamic load analysis. Adv Mech Eng2017; 9: 168781401772185–168781401772112.
38.
KarpatFYuceCDoğanO.Experimental measurement and numerical validation of single tooth stiffness for involute spur gears. Measurement2020; 150: 107043.
39.
LiangXZhangHLiuL, et al. The influence of tooth pitting on the mesh stiffness of a pair of external spur gears. Mech Mach Theory2016; 106: 1–15.
40.
YılmazTGDoğanOKarpatF.A comparative numerical study of forged bi-metal gears: Bending strength and dynamic response. Mech Mach Theory2019; 141: 117–135.
41.
DoğanOKarpatF.Crack detection for spur gears with asymmetric teeth based on the dynamic transmission error. Mech Mach Theory2019; 133: 417–431.
42.
CoyJJChaoCH.A method of selecting grid size to account for hertz deformation in finite element analysis of spur gears. J Mech Des1982; 104: 759–764.
43.
LiangXZuoMJPatelTH.Evaluating the time-varying mesh stiffness of a planetary gear set using the potential energy method. Proc IMechE, Part C: J Mechanical Engineering Science2014; 228: 535–547.
44.
MunroRGPalmerDMorrishL.An experimental method to measure gear tooth stiffness throughout and beyond the path of contact. Proc IMechE, Part C: J Mechanical Engineering Science2001; 215: 793–803.
Please find the following supplemental material available below.
For Open Access articles published under a Creative Commons License, all supplemental material carries the same license as the article it is associated with.
For non-Open Access articles published, all supplemental material carries a non-exclusive license, and permission requests for re-use of supplemental material or any part of supplemental material shall be sent directly to the copyright owner as specified in the copyright notice associated with the article.
