Week 1 Spur Gear Challenge

Objective

To find the Equivalent stress, Total deformation and Stress intensity of giving spur gear model and compare the results with Cast Iron, Cast Steel and Cast Bronze as materials.

Pre-requisites

Spur gear model

Boundary Condition

Part type : Spur gear

Materials : Case 1 Cast iron

Case 2 Cast steel

Case 3 Cast bronze

Moment : 10 Nm

Case 1

• Static structural is setup with the given spur gear model.
• The material is specified as Cast Iron.
• The revolute joint constraint is specified for the spur gear in mesh.
• The joint load condition is provided with moment 10Nm and the modedl is set up to rotate 180 degree.
• Mesh : A mesh size of 0.5mm is applied.
• The Mesh is applied and the simulation is run and the result is tabulated.
• The Equivalent stress, Total deformation and Stress intensity is generatred.

Fig 1.1: Equivalent Stress (Cast Iron) Fig 1.2 : Total Deformation Plot (Cast Iron)

Fig 1.3 : Stress Intensity (Cast Iron)

Case 2

• Static structural is setup with the given spur gear model.
• The material is specified as Cast Steel.
• The revolute joint constraint is specified for the spur gear in mesh.
• The joint load condition is provided with moment 10Nm and the modedl is set up to rotate 180 degree.
• Mesh : A mesh size of 0.5mm is applied.
• The Mesh is applied and the simulation is run and the result is tabulated.
• The Equivalent stress, Total deformation and Stress intensity is generatred.

Fig 2.1: Equivalent Stress (Cast Steel) Fig 2.2 : Total Deformation Plot (Cast Steel)

Fig 2.3 : Stress Intensity (Cast Steel)

Case 3

• Static structural is setup with the given spur gear model.
• The material is specified as Cast Bronze.
• The revolute joint constraint is specified for the spur gear in mesh.
• The joint load condition is provided with moment 10Nm and the modedl is set up to rotate 180 degree.
• Mesh : A mesh size of 0.5mm is applied.
• The Mesh is applied and the simulation is run and the result is tabulated.
• The Equivalent stress, Total deformation and Stress intensity is generatred.

Fig 3.1: Equivalent Stress (Cast Bronze) Fig 3.2 : Total Deformation Plot (Cast Bronze)

Fig 2.3 : Stress Intensity (Cast Steel)

Result

The following results were obtained

Sl. No Description Case 1(Cast Iron) Case 2(Cast Steel) Case 3(Cast Bronze)

1 Yeild Strength 1.1e+11 Pa 2.03e+11 Pa 8e+10 Pa

2 Maximum Stress 466.1 MPa 537.39 MPa 522.62 MPa

3 Maximum Deformation 30mm 30mm 30mm

4 Mximum Stress Intendisity 526.53 MPa 537.39 MPa 522.62 MPa

Conclusion

• All the models are in the safe range
• The fracture may occure at the the point where the teeth profile meets the deduntum of the gear.
• The preferred materials is Cast Steel as it has the maximum Yeild Strenght