Assignment 2

Case-1

Material- Cast Iron(Ductile)

Mesh Size: 0.8 mm

Stress Intensity: It is used to predict the stress state (\"stress intensity\") near the tip of a crack or notch caused by a remote load or residual stresses. Stress Intensity factor K determines whether the crack will grow or not.

in terms of polar coordinates.

Results:

Figure 1: Total Deformation(Max. 30 mm)

Figure 2: Von Mises Stress(Max. 370.92 MPa)

Figure 3: Stress Intensity(Max. 413 MPa)

Possible Fracture Locations:

1) At Contact Point, where the two teeth contact each other.

2) Secondary at the root of gear teeth

Case-2

Material- Cast Steel

Mesh Size: 0.8 mm

Results:

Figure 4: Deformation (Max. 30 mm)

Figure 5: Von-Mises Stress (Max. 369.9 MPa)

Figure 6: Stress Intensity (Max. 410.02 MPa)

Possible Fracture Locations:

1) At Contact Point, where the two teeth contact each other.

2) Secondary at the root of gear teeth

Case-3

Material- Bronze Cast

Mesh Size: 0.8 mm

Results:

Figure 7: Deformation (Max. 30 mm)

Figure 8: Von-Mises Stress (Max. 357.05 MPa)

Figure 9: Stress Intensity (Max. 392.12 MPa)

Possible Fracture Locations:

1) At Contact Point, where the two teeth contact each other.

2) Secondary at the root of gear teeth

Results Summary(Comparision):

Figure 10: Summary of Results

Conclusion:

• From the above results, we can conclude that Bronze Cast Gear will fail in the above application due to FOS<1. Hence Bronze cast material is surely not recommended for the above application.
• Both Cast Iron(Ductile) and Cast Steel are suitable for the above application.
• I would recommend Cast Iron as gear material due to high FOS, high strength and lesser density as compared with other materials.