Abstract
This paper focuses on a failure potential for rotary elements used in the agricultural machinery. It presents a structural stress analysis case study which is a comparative analysis using analytical and numerical (finite element method) methods. In the case study, the motion transmission gears of a rotary drum mower have been considered, and the stress distribution on the transmission gears has been investigated considering real loading conditions which were obtained from experimental field operations. The experimental part of the case study was carried out within a clover field. The clover field was harvested by the drum mower, and the loading force on the transmission gears was calculated through torque data measured from tractor power take-off during the harvesting operation. Subsequently, the torque data were used in the finite element method based commercial code to simulate stress distribution on the transmission gears in the digital environment. The simulation results were validated by making comparisons between analytical calculations and simulation examinations based on the material failure criterion. The numerical results and visual print-outs indicated that there was a good correlation between simulation and analytical results, and the stress magnitudes on the transmission gears were within the safe-operating range against maximum dynamic loading conditions. The study presented a simulation-driven stress analysis case study, which contributes to further research into the utilization of engineering simulation technology for agricultural machinery/equipment design.
Similar content being viewed by others
References
U. Rembold, B. Nnaji, A. Storr, Computer Integrated Manufacturing and Engineering (Addison-Wesley Pub. Co., Wokingham, 1993)
S. Jyothirmai, R. Ramesh, T. Swarnalatha, D. Renuka, A finite element approach to bending, contact and fatigue stress distribution in helical gear systems. Proc. Mater. Sci. 6, 907–918 (2014)
H. Bayrakceren, S. Tasgetiren, İ. Yavuz, Two cases of failure in the power transmission system on vehicles: a universal joint and a drive shaft. Eng. Fail Anal. 14, 716–724 (2007)
H.K. Celik, D. Yilmaz, N. Unal, I. Akinci, Failure analysis of a location axle in tracked tractor. Eng. Fail. Anal. 9(3), 282–287 (2009)
C.-Y. Lin, J.-P. Hung, T.-C. Hsu, Failure analysis of reverse shaft in the transmission system of all-terrain vehicles. Eng. Fail. Anal 8(1), 75–80 (2008)
M. Banuta, I. Tarquini, Fatigue failure of a drive shaft. Eng. Fail. Anal. 12(2), 139–144 (2012)
G.K. Nanaware, M.J. Pable, Failure of rear axle shafts of 575 Di Tractors. Eng. Fail Anal. 10, 719–724 (2003)
S. Zouari, M. Maatar, T. Fakhfakh, M. Haddar, Three-dimensional analyses by finite element method of a spur gear: effect of cracks in the teeth foot on the mesh stiffness. Eng. Fail. Anal. 7(6), 475–481 (2007)
Z.-W. Yu, X.-L. Xu, Failure analysis of cracked gear shafts. Eng. Fail. Anal 9(1), 43–48 (2009)
A. Kawalec, J. Wiktor, D. Ceglarek, Comparative analysis of tooth-root strength using ISO and AGMA standards in spur and helical gears with FEM-based verification. J. Mech. Des. 128(5), 1141–1158 (2006)
S. Patil, S. Karuppanan, I. Atanasovska, A. Wahab, Contact stress analysis of helical gear pairs, including frictional coefficients. Int. J. Mech. Sci. 85, 205–211 (2014)
D. Parle, G. Joshi, A. Ambulgekar, S. Kulkarni, Integrated KBE approach for design and analysis of gears. in MSC Software 2013 Users Conference, Nov 18, Irvine, California, USA, Conference & Tech Papers ID: PA290, 2013.
X. Li, C. Li, D. Geng, S. Jiang, B. Huang, Accurate numerical analysis of gear strength based on finite element method. J. Theor. Appl. Inf. Technol. 46(2), 855–860 (2012)
V. Kirov, Comparing AGMA and FEA calculations. Gear Sol. 9, 38–45 (2011)
M.E.B., Maintenance of Green Forage Harvester. Secondary Education Project Agricultural Technologies Lecture Notes, Turkish Ministry of National Education (M.E.B.), Ankara, (145), 2009 (in Turkish).
DATUM-Electronics, PTO Shaft Torque & Power System, Datasheet Series 420, 2007.
M. Akkurt, Machine Elements-Power and Motion Transmission Elements, vol. 3 (Birsen Publication, Istanbul, 1982). (In Turkish)
F.C. Babalik, Machine Elements and Construction, vol. 3. Uludag University Publication No: 193, Bursa, 2002 (in Turkish).
P. Dabnichki, A. Crocombe, Finite element modelling of local contact conditions in gear teeth. J. Strain Anal. Eng. Des. 34(2), 129–142 (1999)
G. Maitra, Handbook of Gear Design (Mc. Graw Hill, New Delhi, 1994)
H. Rende, Machine Elements-Calculations and Constructions, vol. 2 (Sec Publication, Turkey, 1997). (in Turkish)
Z. Wei, Stresses and deformations in involute spur gears by finite element method, MSc thesis, University of Saskatchewan, Canada, 2004.
B. Hamrock, B. Jacobson, S. Schmid, Fundamentals of Machine Elements (WCB/McGraw-Hill, Boston, 1999)
O.A. Avcil, The design of spur and helical involute gears with computer support, MSc.Thesis, Yildiz Teknik University, 2006 (in Turkish)
P. Kurowski, B. Szabo, How to find errors in finite element models. Mach. Des. 9, 93–98 (1997)
G. Krutz, L. Thompson, P. Claar, Design of Agricultural Machinery (Wiley, New York, 1984)
N. Sakakibara, Finite Element in Fracture Mechanics. Lecture Notes (The University of Texas, Austin, 2008)
Acknowledgments
This paper is part of PhD research presented in the thesis of Dr. Celik, supported financially by The Scientific Research Projects Coordination Unit of Akdeniz University (Turkey) (Project No: 2011.03.0121.006). The authors would also like to express gratitude to Dr Allan E. W. Rennie (Lancaster University, United Kingdom) for his invaluable support and useful discussions throughout this research work.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Kursat Celik, H., Akinci, I. Analytical and Finite Element Method Based Stress Analysis of Rotary Elements: Case Study for the Motion Transmission Gears of a Rotary Drum Mower. J Fail. Anal. and Preven. 16, 293–301 (2016). https://doi.org/10.1007/s11668-016-0084-3
Received:
Revised:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11668-016-0084-3