Abstract:
inertial forces on the contact stress behavior of helical gears in an electric vehicle single-speed
transmission. The analysis was conducted by using a multibody dynamic simulation model in MSC
ADAMS 2020 and ANSYS Workbench 2023 R1 static modeling software. AISI 4340 steel was
chosen as the optimal material based on its material properties advantages such as high strength,
wear, and fatigue resistance. The results indicated that the contact force and stress increased
sharply at the first meshing stage when the gear became engaged and the load was transferred.
Then, at the early engagement phase, as a result of increased interfacial resistance partially
dissipating the transmitted energy as friction increases, thereby reducing the effective normal force
and contact stress. Progressively, the effects of sliding relatively reduce and the process of elastic
interaction is dominant. Then the dynamic friction causes an increase in contact force and stress
to the peak point. After the pitch point, increasing the dynamic friction accelerates the stress
reduction. From this finding, the stress is distributed asymmetrically across the meshing cycle.
Moreover, this research revealed that the higher the helix angle leads to reduction in the contact
stress, but the normal contact force is also observed to increase. This finding indicates that during
an increase in helical angle, the extended contact area has more dominance than the increase in
contact force on the contact stress reduction. The effects of gear inertia force show little more
increase in the contact force and stress under frictionless conditions. The contact force and stress
were produced less than 1 % of the applied load. Finally, the dynamic simulation and ANSYS static
results were validated with the help of theoretical formulation and by comparing with the existing
literature sources, which showed a strong agreement and verified the consistency and accuracy of
the model to predict the contact behavior under dynamic loading conditions
