Week 1 Spur Gear Challenge

Results of Simulation:

S.No	Material	Cast Iron	Cast Steel	Cast Bronze
1	Coefficient of Friction	0.15	0.42	0.15
2	Equivalent (von-Mises) Stress Maximum(Mpa)	359.63	370.1	358.86
3	Stress Intensity Maximum(Mpa)	379.13	394.56	385.02
4	Total Deformation(mm)	30	30	30
5	Maximum Stress Over Time(Mpa)	380.53	453.4	371.42
6	Frictional Stress(Mpa)	61.631	184.9	54.51
7	Maximum Frictional Stress(Mpa)	81.852	256.31	80.331
8	Maximum Penetration(mm)	0.0021195	0.0012306	0.0025775

Data:

• Moment applied: 10N.m
• Tensile Ultimate Strength

1. Cast Iron = 240Mpa

2. Cast steel =505Mpa

3. Cast Bronze =267Mpa

• Maximum von-mises stress

1. Cast Iron = 359.63

2. Cast steel =370.1

3. Cast Bronze =358.86

• Factor of saftey Calculations for all Materials:

Fos= Maximum Tensile stress/Maximum working stress

1. Cast Iron :

FOS = 240/359.63 = 0.6673 <1 Not Safe( Fail)

2.Cast Steel:

FOS = 505/370.1 = 1.36449 >1 Safe

3.Cast Bronze:

FOS = 267/358.86 = 0.744 <1 Not Safe(Fail)

• Penetration is minimum for Cast Steel Compared to other two materials.
• Frictional stress is more in case of Cast Steel as compared to other as its coefficient of friction is very large , in order to reduce frictional losses use lubricant so that the working stress developed will be further less.
• Total deformation is same in all three materials in simulation results.

Not able to find S-N curves for materials. So in simulation i am not able to find Life as well as factor of saftey. If S-N curves are there the results would be more accurate.

Conclusion: Cast Steel is good material to use for this design.