Structural analysis of new generation lightened spur gears with dual material

In this thesis, the stress, modal and dynamic analysis of the new generation lightened hybrid spur gear wheels designed from steel and composite material are carried out by numerical methods. The effects of different rim thicknesses of hybrid gears on the stresses in the root and joint regions, natural frequencies, single tooth and mesh stiffnesses, static transmission error and dynamic factor are obtained and these values are compared with standard steel and lightened steel gears. As a result of the comparison, the most suitable parameters in terms of weight reduction were determined. In the stress analysis of hybrid gears, the joint region thickness is defined by the cohesive zone method without zero thickness, and the joint region thickness is taken into account in finding deformations. In order to obtain dynamic factor and static transmission errors, gear motion equations with 2 degrees of freedom are programmed in MATLAB environment. According to the results, after 1.5xm rim thickness, tooth root stresses are very close to the stress occurring in standard steel gear. In terms of single tooth stiffness, it has been observed that hybrid gears are worse than standard steel gears, and much better than lightened gears. According to the results, it can be said that hybrid gears with the same weight and rim thickness are superior to lightened steel gears in terms of both stress and rigidity.