Week 1 Spur Gear Challenge

The results of the simulation using different materials:

case 1: Cast Iron

equivalent stress:

Stress intensity:

Total deformation:

case 2: Cast steel

equivalent stress:

Stress intensity:

Total deformation:

case 2: Cast bronze

equivalent stress:

Stress intensity:

Total deformation:

The animation of the results:

iron: https://drive.google.com/open?id=1QNlMN4GKMs5XpkgZ6NH9u3XAORqT7Jns

steel: https://drive.google.com/open?id=1LmcZgdOBfL5pKiuG_1dDn3HbDCIAPebq

bronze: https://drive.google.com/open?id=1H3UMyAxy5sGJqxgaqxwX9mpvCvoJqxwb

For comparision :

In the given simulation all the models were given a 10 N.m of torque. With everything same but change in material. These were the results. As from the table we see that the least stress was induced in cast Iron. So I would suggest use of cast iron. But however the von misses stresses are way more than the yield strength of the material so from the distortion theory of failure the models are bound to fail after some limit. Increasing the thickness of the gear by 6mm the equivalet (von misses) stress was reduced to 328.4 MPa. So this how we can improve the design.

After increasing the face width we see that the maximum stress has reduced. Stress intensity tells us that, where is the most possible chance of fracture or failure. So from all the above simulations it was found that the root of tooth is bound to fracture. It also makes sense as most bending stress is induced at that very point.