Week 1 Spur Gear Challenge
AIM:Simulation on spur gear using three different materials Cast Iron (Ductile) Cast steel and Cast Bronze analyze the stress Intensity, equivalent stress and total deformation.
OBJECTIVE:
To perform the simulation on spur gear using static structural analysis of Cast iron (ductile), Cast steel, and cast bronze as a material to find the result out the equivalent stress,total deformation and stress intensity and then compare to find the best material that can be used in the manufacturing process.
PROCEDURE:
. Select Static Structural, drag and drop into Project Schematic
. Choose material as per the case, under Engineering Data.
. Under geometry tab, import the given geometry, double-click to open SpaceClaim to register the model
. Then in Mechanical Module, assign a frictional connection between the gear teeth. (Right to Left)
. Assign revolute joints to both the gear. (Ground to Left/Right)
. Under static structural tab, enter the values of rotational motion of the two gears.
. The right gear is made to rotate up to 180deg in six steps of 30deg each.ie from 30 to 180 degrees.
. The left gear is made to rotate with a moment of -10Nm. Negative sign implies counterclockwise motion.
. The entire set up is solved with a mesh element size of 1mm.ie 0.001mm beacuse the dimensions are in meters.
. Total Deformation, Equivalent Elastic Strain, Equivalent Stress and Stress Intensity plots are requested from the solver as outputs
. The same process is repeated for each case by changing the material assigned.
The below conditons are same for all the cases .
.CONTACTS
.JOINTS
The same is for Ground to Left.
.MESHING
The meshing of 1mm is apllied beacuse if we apply lower size mesh then it will take a lot of time , so for the sake of time we have used the mesh sizing of 1mm.
.JOINT ROTATION (RIGHT)
.JOINT MOMENT (LEFT)
MATERIAL SELECTION ,RESULTS AND PLOTS OF ALL THE 3 CASES
.CASE 1: MATERIAL USED IS CAST IRON (DUCTILE)
Used Cast Iron(ductile) as a material, carried out a static structural analysis to find out Equivalent stress, Total deformation and Stress intensity. Found location for possible fracture
.EQUIVALENT STRESS
.EQUIVALENT ELASTIC STRAIN
.TOTAL DEFORMATION
.STRESS INTENSITY
The stress intensity factor, K, is used in fracture mechanics to predict the stress state near the tip of a crack or notch caused by a remote load or residual stresses.We can infer from the pic below that the gear is most likely to fracture at the base of one of its teeth. Indicated by the MAX label.(same for all cases).
.FORCE CONVERGENCE PLOT
.RESULT SUMMARY
.CASE 2: MATERIAL USED HERE IS CAST STEEL
Used Cast Steel as a material, carried out a static structural analysis to find out Equivalent stress, Total deformation and Stress intensity. Found location for possible fracture
.MATERIAL PROPERTIES
.EQUIVALENT STRESS
.EQUIVALENT ELASTIC STRAIN
.TOTAL DEFORMATION
.STRESS INTENSITY
.CONVERGENCE PLOT
.RESULT SUMMARY
CASE 3: MATERIAL USED HERE IS CAST BRONZE
Used Cast Bronze as a material, carried out a static structural analysis to find out Equivalent stress, Total deformation and Stress intensity. Found location for possible fracture
.MATERIAL PROPERTIES
.EQUIVALENT STRESS
.EQUIVALENT ELASTIC STRAIN
.TOTAL DEFORMATION
.STRESS INTENSITY
.FORCE CONVERGENCE
.RESULTS SUMMARY
. COMPARSION OF RESULTS OF ALL THE 3 MATERIALS
|
Gear Material |
Equivalent Stress (MPa) |
Equivalent Elastic Strain |
Total Deformation (mm) MAX |
Stress Intensity (MPa) |
|
Cast Iron |
3.7744e8 |
0.0034401 |
0.03 |
4.0106e8 |
|
Cast Steel |
3.8615e8 |
0.001907 |
0.03 |
4.116e8 |
|
Cast Bronze |
3.7194e8 |
0.004661 |
0.03 |
3.9913e8 |
CONCLUSION: Cast Bronze has the least amount of stress as well as stress intensity. The stress intensity factor is used in fracture mechanics to predict the stress state near the tip of a crack or notch caused by a remote load or residual stresses. so I would choose Cast Bronze as the material for the gears beacuse it will take more time to break (than that of cast iron and cast steel).