Week 1 Spur Gear Challenge

Objective: In this study static structural analysis has done of two spur gear with output results of Equivalent stress, Deformation and Stress intensity. This study is done with comparison result of different material Grey cast iron, Cast steel and Cast bronze and at the final best suitable material will selected. This study is done in Ansys 2022

Introduction:

Spur gears or straight-cut gears are the simplest type of gear. They consist of a cylinder or disk with teeth projecting radially.

Spur gears are used to transfer motion and power from one shaft to another in a mechanical setup. This transference can alter machinery's operating speed, multiply torque, and allow for the fine-tuned control of positioning systems.

Procedure:

1.Geometry

• Input the model as Step format in geometry

2.Material assignment

• Open Engineering Materials and select the required material.
• Grey cast iron is used for initial study material in ANSYS of given material:

Other material property at the time of comparision:

3.Meshing

• For Meshing the body element size =3mm
• For Contact surface meshing = 0.5mm

4.Boundary condition

1. Contact creation

• Select the faces of gear teeth which will be in contact during simulation running
• Definition > type - Frictional
• Advanced > Formulation - Augmented Lagrange
• Geometric Modification > Interface Treatment - Adjust to touch

2. Joint creation

• Create joint for Left gear by Connection > Right click on it > Select joint (firstly for Left gear and then for Right gear)
• Connection Type- Body Ground
• Type- Revolute

3. Analysis Setting

• Apply number steps= 6 of 180-degree rotation

• Left gear setting with Definition > Type- Rotation

• Right gear setting with Definition > Type- Moment

Results (output):

Mesh

Meshed Quality: According to mesh matrics the Quality vary from 0 to 1

0 for poor Quality element

1 for best Quality element

In our case Mesh of maximum element lies in between 0.7 to 0.9 so it is good as per Quality scale

Deformation

Max deformation= 30mm

Stress

Max stress=467.6 Mpa

Stress intensity

Max Stress intensity =512.96 Mpa

Now compare these results for different material by parametric study by selecting the P symbol as above results which will required for comparing

Conclusion:

By design point of view, Cast Bronze is good as per design view because Stress intensity is low and Equivalent stress is also low as compare to other because Stress intensity is stress generation at the crack tip which can be responsible of crack growth which will lead to fracture.