Week 1 Spur Gear Challenge

Aim

Simulation on Spur Gear using three different materials : Cast Iron (Ductile), Cast Steel & Cast Bronze - Analyze the stress intensity.

Objective

To perform the simulation on Spur Gear using static structural analysis using Cast Iron (Ductile), Cast Steel & Cast Bronze as a material to find the result out the equivalent stress, Total Deformation & 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 manufacturing process.

Properties of materials:

1. Cast Iron Ductile

2. Cast Steel Properties

3. Bronze Cast Properties

Procedure

Model Setup

• Choose Static Structural in Ansys Workbench. Select all the materials in material tab, if not availble particular material edit the properties of the material as per requirement.
• Import the geometry file from folder on which FEA needs to be carried out.
• Edit the model using Ansys Mechanical. Here edit the name of individual parts of assembly.
• Name Both gears as : Right Gear & Left Gear.
• For each case assign the material differently in both Left & Right gears.
• Give frictional contacts to bodies with selecting the contact bodies as right gear with 26 faces & left gear with 26 faces which are going to come in contact while rotation.
• Assign revolute joint to both gears with revolute as ground to left & ground to right.
• Revoulte Joint settings to be changed in properties :

Connection Type - Body-Ground

Type - Revolute

Behaviour - Rigid

Scope - 2 Faces Each

Body - Left to Right

Mesh the bodies with given parameters below

Mesh Settings :

Element Size = 1mm

Use adaptive sizing - No

Smoothing - Low

• In Static Structural assign the joints to the left gear & Right Gear as rotation & moment.

Settings for this:

Joint - Revolute-Ground to left gear & Ground to Right Gear

Type - Rotation to left gear & moment to right gear

Magnitude - Tabular data

Tabular data :

Steps - Time (s) - Rotation (Degree)

1 - 0 - 0

1 - 1 - 30

2 - 2 - 60

3 - 3 - 90

4 - 4 - 120

5 - 5 - 150

6 - 6 -180

For Right Gear Moment Tabular data :

• Press Solve and the simulation will be done.

Result of Case 1: Cast Iron - Ductile

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

Stress Intensity : Stress intensity is measure of stress fields and distribution around a formed cracks in form of fracture mechanics and is a fundamental parameter used to study crack propagation leading to failure.

Total Deformation : It shows the maximum and minimum deformation possible in the Spur Gears when it runs for its application.

Result of Case 2: Cast Steel

Equivalent Stress:

Stress Intensity:

Total deformation:

Result of Case 3: Cast Bronze

Equivalent Stress:

Stress Intensity:

Total deformation:

Discussions:

• Equivalent Stress:

Equivalent Stress for Cast Iron Ductile :

Minimum = 8.9e-8 MPa , Maximum = 5.83 MPa

Equivalent Stress for Cast Steel :

Minimum = 1.16e-7 MPa , Maximum = 6.9 MPa

Equivalent Stress for Bronze Cast :

Minimum = 4.85e-8 MPa , Maximum = 2.85 MPa

• Stress Intensity:

Stress Intensity for Cast Iron Ductile :

Minimum = 9.6e-8 MPa , Maximum = 6.4 MPa

Stress Intensity for Cast Steel :

Minimum = 1.2e-7 MPa , Maximum = 7.6 MPa

Stress Intensity for Bronze Cast :

Minimum = 5.52e-8 MPa , Maximum = 3.1 MPa

• Total Deformation:

Total Deformationfor Cast Iron Ductile :

Minimum = 18.5 mm , Maximum = 30 mm

Total Deformation for Cast Steel :

Minimum = 18.5 mm , Maximum = 30 mm

Total Deformation for Bronze Cast :

Minimum = 18.5 mm , Maximum = 30 mm