Week 1 Spur Gear Challenge

OBJECTIVE:

To determine and compare the total deforamtion. equivalant stress and stress intensity of Spur Gear with the following materials:

1. Cast Iron
2. Cast Steel
3. Cast Bronze

FE Inforamtion:

• The spur gear model is discretized with TETRA mesh of average size 1mm.
• Symmetric frictional contact defined between the left and right gears.
• Augmented Lagrange contact formulation used.
• Both the gears are constrained using revolute joints.
• The left gear is given rotation as input and right gear is given a moment as resistance of 10Nm.

Results:

Total Deformation: 30mm total deformation found in all three cases (not relevant in this study).

Equivalant Stress:

Effective Elastic Strain:

Stress Intensity:

	Cast Iron	Cast Steel	Cast Bronze
Total Deformation (mm)	30	30	30
Equivalant Stress (MPa)	364.87	387.63	361.39
Effective Elastic Strain	0.0040901	0.0019143	0.0045288
Stress Intensity (MPa)	386.49	413.18	387.85

Conclusion:

1. Chances of crack initiation where the stress intensity is the highest in the model.
2. Based on the simulation results, Cast Iron and Cast Bronze are found to be better materials for spur gear compared to Cast Steel material as the equivalant stress and stress intensity is lower in these cases.