An Integrated Approach for Contact Stress Analysis of Aluminium Composite Gears through Finite Element Analysis and Experimental Test Rig Testing Under Misalignment

Aluminium composite gears combine the benefits of aluminium and other materials to produce robust, light, and corrosion-resistant gear. The present investigation offers a comprehensive method for assessing the contact stress in a hybrid nano-composites gear made of aluminium 6061-SiC–B4C–GO using experimental testing and Finite Element Analysis (FEA). The experimental testing was carried out on a specialized test rig that can apply different misalignments to the gears and use strain gauges to measure the contact stress. The contact stress distribution on the gear teeth is predicted using the FEA simulations. There is an acceptable level of agreement, proving the effectiveness and accuracy of the integrated approach when the findings from the two techniques were compared. The study shows the efficacy of an integrated strategy for assessing the contact stress of gears under misalignment. It offers valuable insights into the behaviour of contact stress in aluminium composite gears. The findings of this study can be used to improve the design and performance of aluminium composite gears, leading to more efficiency and reliability even under misalignment for machinery. © The Institution of Engineers (India) 2023.