Week 1 Spur Gear Challenge
STATIC STRUCTURAL ANALYSIS ON SPUR GEAR
Objective: To carry out a Static Structural analysis on spur for Equivalent stress, Total deformation and Stress intensity using below mentioned material;
Case 1:Cast Steel
Case 2:Cast Bronze
Case 3:Cast Iron
The aimis to conclude and choose the best metrial on the basis of reports.
Setup For Simulation:
Geometry:
The geometry is imported in static structural panal using import geometry feature present in geometry tab, the model is imported for static structural analysis.
The geometry imported is a pair of spur gear named as right gear and left gear with 13 teeth each.
Material Property:
Case 1:Cast Steel
Case 2:Cast Bronze
Case 3:Cast Iron
The material used for spur gear to carry out analysis is mentioned above for all the three cases ;
Case 1:Cast Steel
Case 2:Cast Bronze
Case 3:Cast Iron
Analysis is carried out individuall for each case.
Connection details:
The type of contact chosen for the given gear drive for driver and driven gear is considered as frictional contact and formulation is chossed as augmented lagrange to minimise the interference . To avoid penetration interference treatment is chosen asadjust to touch.
Joint details:
Here, both the gear are provided with revolute joint with ground to gear contact , gear_1 is provided with DOF of rotation along Z azis with type as rotation and increment of 30 degree and gear 2 is provided with DOF of rotation along Z axis with type as moment of -10000N - mm.
Meshing:
The mesh size is provided to be 1mm and the type of mesh is HEXA. The no of nodes is the mesh are 16474 and no of elements are 2808 . It is possible to refine the mesh further for better reports depending upon the version of software and system specifications.
Joint load details:
Gear one is considered as driven gear hence, rotation of 180 degree is considered at an increment of 30 degree, therefore gear2 has to be driven gear since the moment of -10000N-mm is provided
Results:
Total deformation:
Case 1:Cast Steel
Case 2:Cast Bronze
Case 3:Cast Iron
Equivalent Stress:
Case 1:Cast Steel
Case 2:Cast Bronze
Case 3:Cast Iron
Stress Intensity:
Case 1:Cast Steel
Case 2:Cast Bronze
Case 3:Cast Iron
Tabular Report Comparison For All The Three Cases:
| Analysis | Case 1 (cast steel) | Case 2 (cast bronze) | Case 3 (cast iron) |
| Min Total deformation | 18.5 mm | 18.5 mm | 18.5 mm |
| Max Total deformation | 30 mm | 30 mm | 30 mm |
| Min Equivalent Stress | 5.6396e-5 MPa | 4.7222e-5 MPa | 4.2118e-6 MPa |
| Max Equivalent Stress | 386.15 MPa | 371.93 MPa | 467.52 MPa |
| Min Stress Intensity | 6.3491e-5 MPa | 5.1357e-5 MPa | 4.4965e-6 MPa |
| Max Stress Intensity | 411.6 MPa | 399.11 MPa | 527.55 MPa |
Conclusion:
From the above table it is observed that 30 mm is the max deformation in all the cases and 18.5 mm is the min.
The maximum value of Equivalent stress developed is in cast iron gear is 467.52 MPa whereas, the maximum Equivalent stress developed in cast bonze spur gear is
371.93 MPa which is least in all the three gears .
Hence, from the results of Equivalent stress and Total deformation for all the spur gear, case-2: Cast bronze is the preferred choice of material.
The maximum value of stress intensity is developed in cast iron spur gear is the highest of all, 527.55 MPa whereas, the maximum stress intensity developed in cast bronze spur gear is the least , 399.11 MPa.
From the results of Stress intensity for all the cases of spur gear, case-3:Cast Iron is the gear with highest max stress intensity value of material so according to stress intensity report for durability Cast iron is the prefered material.
But, practically no material mentioned in the above three cases can be and should be used for real life application.
NOTE: Please access text file attached for drive link for .wbpj and .wbpz files for analysis.