Static Structural analysis of Spur Gear using Ansys with three different materials

Aim:

To carry out a static structural analysis to find out Equivalent stress, Total deformation and Stress intensity(Learn about what stress intensity is). Find location for possible fracture by simulating spur gear using 3 different material, ie Cast Iron (ductile),cast Bronze, Cast steel.

Solution (Step by Step):

From Engineering Data, required materials, has been added from Granta Design sample materials in the academic version of ANSYS.

The corresponding model has been added in spaceclaim and verified and moved to model section.

Contacts and Joints:

The surfaces for contacts and targets are selected and the type of joint is made as frictional,

RRevolute joint has been selected for both the gears,

,Meshing:

Face sizing done with element size of 0.75mm in the contact and target surfaces, other not important regions are meshed with size around 6mm.

IIn analysis setting the gear is rotated in 6 steps and the timing steps as follows,

Then the joint loads are applied as follows

Solution:

The Total deformation, Equivalent Stress and Stress Intensity is generated for all the 3 materials, Cast Iron(Ductile), Cast Bronze, and Cast Steel.

S.NO Material Total Deform(in mm) Equ.Stress (MPa) Intensity.(MPa)

1 CI 30 379.65 411.24

2 CB 30 305.57 322.47

3 CS 30 383.11 410.38

Conclusion:

Upon Comparing the results, we would suggest to use the Cast Bronze for the design, as other material which has higher stress value and intensity when compared with Cast bronze. and the stress intensity is maximum in bottom of teeth in cast bronze, so the possibility fracture might happen at that point.

Note: For Cast iron and steel, the stress values are higher and it happens in the mid of teeth,say near the circular pitch region in teeths face.