Week 1 Spur Gear Challenge
##COMMENTS BY GRADER:
Hey Santosh,
Good job on completing the challenge and the report. I would like to suggest you to compare the results of each of them side by side next time.
##
SPUR GEAR CHALLENGE
The model is downloaded from the internet and imported into space claim
MESHING
Elment size of 1mm is given to give a refined mesh feel and the no of nodes and elements comes under the academic limit
CONTACT
The 26 faces of right spur are selected as contact and 26 faces of the left spur are selected as target
And type of contact is defined as friction with the type of equations to be solved be augmented lagrange
ANALYSIS SETTINGS
6 substeps are defined with the initial substep as 0.2s,minimum time step as 5e-2s,maximum time step as 0.5s.Large deflection is switched on
CONSTRAINING
Body to ground revolute joint is defined by defining the inner rim as the scope for both left and right spur
DEFINING MOVEMENT
For the left spur the revolute joint is defined by rotation and is allowed to turn till 180 degrees( 30 degrees every step added)
For right spur a moment -10Nm is defined for all the six sub steps
Simulation is solved for total deformation,equivalent stress and equivalent strain
CASE 1:CAST IRON DUCTILE AS MATERIAL
OBSERVATIONS
DEFORMATION PLOT
STRAIN PLOT
STRESS PLOT
STRESS INTENSITY
FATIGUE
CASE 2:CAST STEEL
OBSERVATIONS
DEFORMATION
STRAIN PLOT
STRESS PLOT
Stress Intensity
Failure
CASE 3:CAST BRONZE AS MATERIAL
DEFORMATION PLOT
STRAIN VALUES
STRESS PLOT
STRESS INTENSITY
FAILURE
RESULTS
The maximum equivalent stress is greater in cast steel ,greater by a magnitude of 13.07Mpa in cast iron,greater by a magnitude of 32.11Mpa.
The deformation is the same on all the materials
The fracture mainly accurs at the point where point occurs due to frequent rubbing of teeth
Stress intensity is highest in cast steel,it is greater by a magnitude of 75Mpa in comparison to cast bronze and greater by a magnitude of 8 Mpa in comparison to cast iron
Maximum equivalent strain is highest in cast bronze,higher by am magnitude of 0.00246mm/mm in comparison to cast steel and higher by a magnitude of 0.0022mm/mm in comparison to cast iron
Cast Bronze is best suited for making spur gear because stresses induced are comparitively lesser and stress intensity is the least