Modeling and Analysis of Gear Tooth Replacement System Against Breaking of Single Tooth

Abstract A gear is a mechanical machine part that transmits motion by successfully engaging teeth and gives the impression of positive action by coordinating and interlocking precise effort to achieve the desired result. Gear design necessitates a thorough investigation, and the loads, as well as the gear parameters, were determined by trial and error. When a single tooth on any gear breaks, the transfer of power is halted, resulting in material, time, and cost waste. The design and development of spur gear with teeth portability is the subject of this research paper. ANSYS is used to perform gear design analysis. To ensure precision, a wire cut electric discharge machine is used to cut each tooth, which is then assembled into gear using a gear blank, cover plate, nut, and bolt. The results of the analysis performed in the program Ansys 15.0 show that the proposed portable tooth spur gear can withstand maximum principal stress of 1.1886 × 108 Pa and total deformation that will occur at this stress 5.7897 × 10(−6) m. If the portable tooth spur gear is used, the cost of replacing all 65 teeth would be about 3000 Rupees. Keeping this in mind, replacing all 65 teeth twice a year would cost about 11500 Rupees, which is less than the total cost of the traditional gear design. In comparison to the conventional gear design, the proposed design reduces long-term maintenance costs.