Week 1 Spur Gear Challenge
Aim: To Simulate the bevel gear using cast iron, cast steel, and cast bronze to conclude which material you would recommend.
Software used: Ansys WorkBench 2020 R2
Geometry:
Mesh:
Solution setup:
- Defined revolute joint to left gear and the Moment to the right gear and I have simulated 6 steps.
- Defined Initial, min. and max. time steps as 0.2 s, 0.05 s, and 0.5 s.
- Here I have simulated 6 steps.
1. Cast Iron(ductile):
Total Deformation:
- Max. deformation is 0.03 mm
Equivalent stress:
- Max. Equivalent stress is 342.36 Mpa
Stress Intensity:
- Max. Stress Intensity developed is 376.97 Mpa
2. Cast Steel:
Total Deformation:
- Max. deformation is 0.03 mm
Equivalent stress:
- Max. Equivalent stress is 222.06 Mpa
Stress Intensity:
- Max. Stress Intensity is 392.72 Mpa
3. Cast Bronze:
Total deformation:
- Max. deformation is 0.03 mm
Equivalent stress:
- Max. Equivalent stress developed is 341.05 Mpa
Stress Intensity:
- Max. Stress Intensity is 373.42 Mpa
Comparison:
| Max. Deformation (mm) | Max. Equivalent Stress (MPa) | Max. Stress Intensity (MPa) | Yield strength (MPa) | Ultimate Strength (MPa) | |
| Cast Iron | 0.03 | 342.36 | 373.97 | 79.81 | 141.14 |
| Cast Steel | 0.03 | 222.06 | 392.72 | 349 | 505 |
| Cast Bronze | 0.03 | 340.05 | 373.42 | 144 | 267 |
Conclusion:
- In comparison, we can clearly see that Max. stress developed in Cast Iron and Cast Bronze is exceeded their yield strength and ultimate strength whereas the stress developed in the cast steel is less than its yield strength. Thus, I will recommend going with cast steel for the production.