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The Design – Design Helical Gear Simulation | ANSYS CFX

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Helical or “dry fixed” gears offer a refinement over spur gears. The leading edges of the teeth are not parallel to the axis of rotation but are set at an angle. Since the gear is curved, this angling makes the tooth shape a segment of a helix. Helical gears can be meshed in parallel or crossed orientations. The former refers to when the shafts are parallel to each other; this is the most common orientation. In the latter, the shafts are non-parallel, and in this configuration, the gears are sometimes known as “skew gears”.

The angled teeth engage more gradually than do spur gear teeth, causing them to run more smoothly and quietly. With parallel helical gears, each pair of teeth first make contact at a single point at one side of the gear wheel; a moving curve of contact then grows gradually across the tooth face to a maximum, then recedes until the teeth break contact at a single point on the opposite side. In spur gears, teeth suddenly meet at a line contact across their entire width, causing stress and noise. Spur gears make a characteristic whine at high speeds. For this reason, spur gears are used in low-speed applications and in situations where noise control is not a problem, and helical gears are used in high-speed applications, large power transmission, or where noise abatement is important. The speed is considered high when the pitch line velocity exceeds 25 m/s.

A disadvantage of helical gears is a resultant thrust along the axis of the gear, which must be accommodated by appropriate thrust bearings. However, this issue can be turned into an advantage when using a herringbone gear or double helical gear, which has no axial thrust – and also provides self-aligning of the gears. This results in less axial thrust than a comparable spur gear.

The second disadvantage of helical gears is also a greater degree of sliding friction between the meshing teeth, often addressed with additives in the lubricant.

In this analysis, it has been tried to analyze the simulation of design helical gear, using the ANSYS CFX software.

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The Design – Design Helical Gear Simulation | ANSYS CFX

Helical or “dry fixed” gears offer a refinement over spur gears. The leading edges of the teeth are not parallel to the axis of rotation but are set at an angle. Since the gear is curved, this angling makes the tooth shape a segment of a helix. Helical gears can be meshed in parallel or crossed orientations. The former refers to when the shafts are parallel to each other; this is the most common orientation. In the latter, the shafts are non-parallel, and in this configuration, the gears are sometimes known as “skew gears”.

The angled teeth engage more gradually than do spur gear teeth, causing them to run more smoothly and quietly. With parallel helical gears, each pair of teeth first make contact at a single point at one side of the gear wheel; a moving curve of contact then grows gradually across the tooth face to a maximum, then recedes until the teeth break contact at a single point on the opposite side. In spur gears, teeth suddenly meet at a line contact across their entire width, causing stress and noise. Spur gears make a characteristic whine at high speeds. For this reason, spur gears are used in low-speed applications and in situations where noise control is not a problem, and helical gears are used in high-speed applications, large power transmission, or where noise abatement is important. The speed is considered high when the pitch line velocity exceeds 25 m/s.

A disadvantage of helical gears is a resultant thrust along the axis of the gear, which must be accommodated by appropriate thrust bearings. However, this issue can be turned into an advantage when using a herringbone gear or double helical gear, which has no axial thrust – and also provides self-aligning of the gears. This results in less axial thrust than a comparable spur gear.

The second disadvantage of helical gears is also a greater degree of sliding friction between the meshing teeth, often addressed with additives in the lubricant.

In this analysis, it has been tried to analyze the simulation of design helical gear, using the ANSYS CFX software.

Geometry & Grid

The geometry required for this analysis was generated by Ansys Design Modeler software. The meshing required for this analysis was also generated by Ansys Meshing software. The mesh type used in this analysis is unstructured. The total number of volume properties for geometry is 3,8547e+006 mm³.

Model

In this analysis,  a transient analysis type was used to obtain the results to check the fluid flow. In this analysis, non-buoyant models have been used and stationary domain motion has also been activated in this analysis. In this analysis, a k-Epsilon model was used to study the water flow and thermal energy fluid models of heat transfer.

Boundary Condition

The flow input for this geometry of a helical gear that directs the flow of air at a fluid temperature of 25 C into the geometry. The turbulence boundary condition of a helical gear wall is considered to be k-Epsilon according to the working conditions. The wall function is defined as Scalable in the name selection section of turbulence boundary condition. The static pressure for the design modeler is set as relative pressure equal to 1 atm.

Discretization of Equations

In this analysis, high-resolution is used for the advection scheme of the basic settings. In this analysis, the first-order is used for turbulence numerics. In this analysis, the residual type of convergence criteria is RMS and the residual target of convergence criteria is 1.E-4.

The results are presented as pressure contours as well as streamlines.

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