FEM Study on the Efficiency of 3D Printed Gears

Abstract

This paper presents the 3D modeling and static structural analysis in ANSYS of a spur gear set manufactured from four different materials: two conventional steels, 36Mn5 and 18CrNiMo7 and two 3D printable Ultrafuse 17-4PH and 316L. The study aimed to compare maximum elastic deformations, Von Mises stresses, and material-specific mechanical properties in order to evaluate their suitability for gear applications. Significant differences were observed in hardness, yield strength, and wear resistance. The carburized steel 18CrNiMo7 exhibited superior strength and hardness, confirming its suitability for heavy-duty industrial transmissions, while 36Mn5 proved adequate for moderate-load applications. Among the Ultrafuse materials, 17-4PH demonstrated a favorable compromise, with acceptable ductility and the potential for post-printing heat treatment, making it suitable for functional prototypes and gears with moderate loads. The analysis concludes that while Ultrafuse materials can be effectively employed in prototyping and testing, carburized steel 18CrNiMo7 remains the recommended choice for industrial series production of gears subjected to high loads and wear.