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, stress

OBJECTIVE:
To perform the simulation on Spur Gear using static structural analysis using Cast iron
(ductile), Cast steel, and cast bronze as a material to find the result out the equivalent
stress, Total deformation, and Stress Intensity.
Analysis of the result on spur gear using three different materials evaluate it and then
compare the best material that can be used in the manufacturing process.

SUMMARY:
To solve the simulation problem using the FEA method on Ansys workbench. First, assigning
the material such as Cast Iron (ductile), Cast steel, and Cast bronze from the library using
the static structural and then open the model in Ansys mechanical with remaining the
geometry for the gear are left-side gear.
To evaluate the model setup need to be done with respect to mesh size, joints, joint load in
static structural, and giving the analysis settings and then generating the result.

Properties of materials:
1) Cast Iron Ductile

2) Bronze cast

3) Cast steel

PROCEDURE: 1) Cast Iron Ductile

Model setup
Geometry rename

1. Left side gear

2. Right side g

Material selection :

geometry> component> material> assign material

image shows the how to assign material:

Giving the frictional contacts to the bodies with selecting the contact bodies as right gear
with 26 faces and the target bodies as a left gear with 26 faces.

Assigning the revolute joint to both gears as a ground to left gear and ground to the right
gear

Revolute joints Settings:

Connection Type	Body-Ground
Type	Revolute
Behavior	Rigid
Scope	2 Faces each
Body	left and right
Mesh Settings:	Element Size 1mm
Smoothing	Low
Use adaptive sizing	No

Checking the mesh metrics as the element quality for 1mm size.

In static structural assign the joints to the left gear and right gear as rotation and a
moment.
The left gear is assigned as rotation and the right gear is assigned as a moment.

Settings:

Joint	Revolute- Ground to left and Ground to right
Type	Rotation to left gear and moment to the right gear
Magnitude	Tabular data

Tabular data
Steps Time [s] Rotation [°]
1 1 0. 0.
2 1 1. 30.
3 2 2. 60.
4 3 3. 90.
5 4 4. 120.
6 5 5. 150.
7 6 6. 180.

	Steps	Time [s]	Moment [N·m]
1	1	0.	-10
2	1	1	-10
3	2	2	-10
4	3	3	-10
5	4	4	-10
6	5	5	-10
7	6	6	-10

RESULT:
Generating the result for the setup of the spur gear, checking the solution for equivalent
stress, stress intensity, and total deformation.
Results obtained for the cast Iron (ductile) after solving each node for the meshing and
running the simulation.

Case 1:

Cast Iron is a group of Iron-carbon alloys contains 2% more carbon. It derives from its
relatively low melting temperature. cast iron tends to be brittle except for malleable cast
iron. This material is used in the automotive industry such as cylinder heads, cylinder
blocks, and gearbox cases. It is resistant to damage by oxidation.

Equivalent stress:
The name suggests as maximum stress is produced in the spur gear when it runs for its
application. It predicts the yielding of materials under multiaxial loading conditions using
the result from simple uniaxial tensile stress.

Total Deformation

strain:

Case 2:

Cast Steel is a ferrous alloy with a maximum carbon content of approximately 0.75%. steel
castings are solid metal objects produced by filling a void within a mold with liquid steel. A
they are available in many same carbons and alloy steels that can be produced as
wrought metals.

result for cast steel as shown bellow:

total deformation :

Equivalent elastic strain:

Equivalent stress:

Case 3
Cast Bronze is the most popular metal for cast metal sculptures is simply called bronze.
They can be used for statues, singly or in groups, reliefs, and small statuettes and figurines
as well as bronze elements and, can be fitted to other materials.

Result image for bronz material :

Total deformation :

The total deformation for all three materials approximately is the same, which states that
the force applied on the body with carrying each material respective will have the same
deformation.

Equivalent elastic strain:

Equivalent stress:

Stress intensity factor is used in fracture mechanics to predict the stress near the tip of the
crack caused by a remote load or residual stresses. The graph indicates that the cast steel
has maximum stress intensity approx 3.4267e08 MPa and minimum stress 0.49636MPa but the
cast bronze has less stress instensity compare to other materials.

Note:

I have attached zip file in which all the analysis is done

link for the animation for cast iron : https://drive.google.com/file/d/1giGGRw0bbPzQ6MedGI7tZLoowXZDy_Cs/view?usp=sharing