Week 1 Spur Gear Challenge

Aim-

• Case 1:
  

                   Using Cast Iron(ductile) as a material, carry out a static structural analysis to find out Equivalent stress, Total deformation and Stress intensity(Learn about what stress intensity is). Find location for possible fracture

• Case 2:

                   Using Cast Steel as material, perform the same analysis for the results as in Case 1.

• Case 3:

                   Using Cast Bronze as material, perform the same analysis for the results as in Case 1.

Objective 2:

                Write a detailed report comparing the results of the three cases and conclude which material would you recommend based on these results.

Procedure-

1) Drag the static Structural into the project schematics and rename the project, now open engineering data to choose the matrials

2) now import the geomerty by right clicking on geometry and import, then double click on geometry to open spaceclaim to check for any abnormality, if everthing is correct, exit spaceclaim

3) open model browser and select the part which we want to apply new material and assign by clicking on matrials in details view

4) Go to Connections and rename them based upon their defination

now select every contact face of gear and update geometry, change the type from bonded to frictional, Behaviour To symmetric, formulation to Augmented Lagrange, interface treatment to adjust to touch.

now define BODY TO GROUND Revolute joints for each gear

5) Now go to mesh and enter element size as 0.75mm, and change smoothing to low

6) in analysis settings, add 6 time steps , select all time steps and switch on auto time stepping, change define by to time, initial time step to 1sec, minimum time step to 0.1sec, maximum time step to 1 sec, turn on large deflection

now insert joint load, type- roatation, data tabuler and enter 0,30,60,90,120,150,180 degrees in each time step

insert another joint load, type-moment and enter -10N-m for each time step

7) in solution add Equivalent stress, Total deformation and Stress intensity and solve

CASE 1 ( Cast iron ductile)

CASE 2 (Cast Steel)

CASE 3 ( Cast Bronze)

Conclusion- 

Stress Intensity - it is a state of stress near discontinuety or near notch and it signifies that at the perticular loaction the fracture may start.

For this Assembly Cast Steel is best material beacuse its yeild strength is 249MPa where for cast iron it is 244MPa and in both stress developed are almost same, bronze will not be recomended.