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 metals.                                                                                                              Prerequisites:                                                                                                                                                                        Spur gear model

Boundary condition:-

Part Type:- Spur gear

Materials:- Case 1 Structural steel

                 Case 2 Cast steel

                 Case 3 Cast Bronze

Moment:-  10Nm 

Case 1:- 1. static structural is set up with the given spur gear model.

             2. The material is specified as structural steel

             3. The revolute joint constrained is specified for the spur gear in the mesh.

             4. The joint load condition is provided with the moment 10 N m and the model is set up to rotate 180 degrees.

             5. Mesh:- A mesh size 0f 0.5 mm is applied.

             6. The mesh is applied and the simulation is run and the result is tabulated.

             7. The equivalent stress, Total Deformation, stress intensity is generated.

                                 Fig 1. Equivalent stress ( Structural steel)

                                                     Fig 2. Total Deformation ( Structural steel )

                                                  Fig 3. Stress Intensity ( Structural steel )

Case 2:-

1. Static structural is setup with the given spur gear model

2. The material is specified as Cast bronze

3. The revolute joint constraint is specified for the spur gear in a mesh.

4. The joint load condition is provided with a moment 10Nm and the model is setup to rotate 180 degree

5. mesh: A mesh size of 0.5mm is applied.

6. The mesh is applied and the simulation is run and the result is tabulated.

7. The Equivalent stress, Total Deformation, and stress Intensity is generated.

                                           Fig 4. Total Deformation ( Cast steel )

                                      Fig 5. Equivalent stress ( Cast steel)

                                   Fig 6. Stress Intensity ( Cast steel )

Case 3:-

1. Static structural is set up with the given spur gear model.

2. The model is specified as Cast bronze.

3. The revolute joint constraint is specified for the spur gear in the mesh.

4. The joint load condition is provided with a moment of 10 Nm and the model is set up to rotate 180 degrees.

5.mesh: A mesh size of 0.5mm is applied.

6.The mesh is applied and the simulation is run and the result is tabulated.

7. Equivalent stress, Total Deformation, and stress Intensity is generated.

                                           Fig 7. Total Deformation ( Cast bronze)

                                          Fig 8. Stress Intensity ( Cast bronze )

                                           Fig 9. Equivalent stress ( Cast bronze)

S.No       Description                case 1  ( structural steel)           case 2 ( cast steel )             case 3 ( cast bronze )

1.           yield strength                 1.11e+11 pa                          2.03 e+11 pa                           8e+10 Pa

2.           Equivalent stress                 386.15                                               386.15                          371.94

3.          Total Deformation             30                                             30                                          30

4.          Stress Intensity                 411.6                                                411.6                           399.13

 Conclusion:-

1.       All the models are in the safe range

2.       The fracture may occur at the point where the teeth profile meets the dedendum of gear.

3.        The preferred material is cast steel as it has max.yield strength.