Week 1 Spur Gear Challenge

Objective: The objective of this project is to simulate static structural analysis using different materials(such as cast iron (ductile), cast steel and cast bronze) and compare their equivalent stress, total deformation and stress intensity of a spur gear.

	Young' modulus(GPa)	Poission ratio	Yield Strength(MPa)	Ultimate strength(MPa)
case 1: cast iron (ductile)	171	0.275	340	548
case 2: cast steel	203	0.3	341	505
case 3: cast bronze	80	0.345	144	267

Geometry:

Contact: Contact was set up between 26 faces of both the spur gears. Frictionless contact has been applied between the two gears.

Revolute Joint: Connection for the spur gears is body to ground. For the left gear an rotation has been set at an interval of 30o in the anticlockwise direction. On the Right gear a moment of 10Nm is applied in the couterclockwise direction.

Meshing:

	Element size(mm)	No of elements	Nodes
All cases	1mm	17860	3088

Equivalent Stress(Von mises) Results all cases:

1. Cast Iron (ductile)

2. Cast Steel

3. Cast bronze

Total deformation for all cases:

1. Cast Iron (ductile)

2. Cast Steel

3. Cast bronze

Stress intensity for all cases:

1. Cast iron(ductile)

2. Cast steel

3. Cast bronze

Results:

Max	Equivalent stress(MPa)	Total deformation(m)	Stress Intensity(MPa)
case 1: cast iron (ductile)	342.7	0.03	358
case 2: cast steel	343	0.03	360
case 3: cast bronze	337.2	0.03	357.7

Results:

From the results we can conclude that the stress is greater than the yield strength and hence undergo plastic deformation. All the regions of max stress intensity act as sites for crack formation which eventually leads to fracture.