Week 1 Spur Gear Challenge

1. Objective :

1. To find equivalent stress, strain, deformation and stress intensity using the attached spur gear model, run the simulation using the three different materials as indicated. Then, assess the results.
2. b) To compare outcomes produced by three distinct materials, Compare each result, then organize them into a table. Additionally, state your choice of material for the spur gear model.

2. Case Setup & Execution

With starting up the workbench and choosing the right material such as steel, Bronze or Cast Iron. As mentioned I have added the following material and provide the input numerical values such as Modulus of Elasticity, Poison’s ratio, Tensile & Ultimate strength of material.

Following the same update the model and edit the same. Then rename the right and left gear and choose the material as required for both the gears. Then Click on contacts and choose the tooth faces as target for left gear and contact for right gear. There must be 26 faces selected as no of tooth are 13.Contacts must be frictional and method should be Lagrange. Next in connection insert joints for both gear and select body-Ground Connection type, also provide the revolute joint as both the gear will be rotated. After providing the respective joints now to run the same gradually include the no of steps as 6 in Analysis setting and provide initial step, minimum step and maximum time step. Keep the steps as minimum so that solver can solve easily. Now I have inserted two joints for both of gears and providing moment of 10N-m for each step to right gear. Similar for the left gear 30deg angle of rotation is provided in 6 equal step.

Now in the solution inserting all the various input such as stress, strain, Stress intensity, deformation as required. Moving to mesh after changing few values form 2.0mm mesh to finally fixing a value of 0.75mm. The mesh size of 0.75mm seem fine and good looking to run the simulation. After generating the mesh, hit solve to run the simulation. The same was repeated with three different materials and files are attached below or reference.

3. Result of Case 1 :

Material – Cast Iron (Ductile) : In this after running the simulation it’s been clearly seen that stress values generated is 369.09 MPA which is higher than steel and lower than Bronze. The stress intensity reaches a maximum value of 421.53MPA. Total deformation is 30 mm Max.

Material – Cast Steel – In Cast steel material there can been seen a significant drop in the values of equivalent stress and stress intensity. The values are 355.52 MPA for & 392.8 MPA. Total deformation remains the same as 30mm.

Material – Cast Bronze –The Bronze material when compared has the maximum value of both above material. Equivalent stress is 421.26MPA & Stress Intensity is 472.05 MPA .Deformation is the same as 30 mm.

4. Conclusion : Comparing all the three materials i.e Cast Iron, Cast Steel & Cast Ductile .

Sr no	Material	Equivalent Stress (MPA)(Max)	Stress Intensity (MPA) (Max)	Deformation (mm) (Max)
1.	Cast_ Iron	369.09	421.53	30
2.	Cast_ Steel	355.52	392.8	30
3.	Cast_ Bronze	421.26	472.05	30

As from the above attached table it can be clearly seen that bronze being one of the weakest material and also have low Modulus of elasticity has developed max stress Value of 421.26MPA and Stress Intensity of 472.05 MPA. So the material that will fail under similar boundary conditions will be Bronze. Other than that Steel has lower value of equivalent stress 355.52 MPA & Stress Intensity 392.8 MPA. So it is one of the material having high modulus of elasticity and will withstand more under similar boundary conditions.

If we rate three of materials based on their current strength then Cast_Steel > Cast_Iron > Cast_Bronze, the most suitable is steel and the least suitable is the Bronze.

Now we see which material to select will completely depend on the cost applied to material ,the assembly in which the gear is required to be installed, the manufacturing difficulties such as hardness of material and many other parameters, This is because if the application is not required to be highly safe then Cast Iron can be used instead of Steel as the Cost of Steel approx 4 times higher than Cast Iron. So material to be selected will completely depend on the assembly, application and many other parameter.

Note - All files images are attached in the code name such as ' Filename_ Material' with respectieve material name in the end. Animation Video of steel attached for Reference . Cast Iron & Cast Steel zip file attached attached in Workbench. Seperate Zip file for Bronze material attached.