Week 1 Spur Gear Challenge

OBJECTIVE:

• To perform the static analysis on the Spur gear, with three different materials in each case

Case setup:

Material creation:-

• Create a new static structural analysis project
• Firstly create the above mentioned material with the given parameters
• Cast iron(ductile) property is shown in below image
  
• Cast Steel material proeprty is shown in below image
  
• Bronze, cast material property is shown in below image
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• Once the required materials are created, next we have to import the geometry

Import geometry:-

• Import the gemoetry from the saved location
• Update the model and enter into ansys mechanical workbench
• Here we can set up the model and require desired output
• For convinience i have renamed the model as right and left
• Now assign the materials to the model

Mesh:-

• Mesh the model with fine mesh
• Mesh element size=0.5mm, in this case we will be Meshing method as Hexa.

Establish connection:-

• Go to connections>select contact and tooth
• Type=frictional,
  Behaviour =symmetric;
  Interface treatment= Adjust to touch;
  Formulation = Agumented lagarange(This option will help in keeping the gears in same position, even after contact)
• Select the tooth of the right gear for contact slection
• Select the tooth of left gear for joint selection

Create joints:-

• Right click on contact>insert>joint
  
• Create joint for each of the gear
  Connection type=Body to ground
  Type=Revolute
  Scope= select the inner portion of the gear

Analysis Setting:-

• 

Create Joint Load:-

• Right click on analysis setting>insert>joint load
  
• Joint load for right side gear
  Joint=Revolute- ground to right
  DOF =Z
  Type=Rotation
  Magnitude=tabular data
  
• Joint load for left side gear
  Joint=Revolute- ground to left
  DOF =Z
  Type=Moment
  Magnitude=tabular data
  

Output request:-

• Request the output for Von misess stress and strain,total deformation, stress intensity
• Right click on the solution>Insert>deformation,stress,strain
• Repeat the same procedure, just the material as to changed

Results:

Case 1(Cast iron):-

• Von mises stress
  
  
• Von mises strain
  
  
• Stress intensity
  
  
• Total deformation
  

Case 2(Cast Steel):-

• Von mises stress
  
  
• Von mises strain
  
  
• Stress intensity
  
  
• Total deformation
  

Case 3(Bronze, Cast):-

• Von mises stress
  
  
• Von mises strain
  
  
• Stress intensity
  
  
• Total deformation
  

Materials	Von-mises Stress(MPa)	Von-mises Strain(mm/mm)	Stress Intensity(MPa)	Total Deformation(mm)
Cast Iron	512.6	0.0050121	586.62	30
Cast Steel	516.52	0.0043571	588.57	30
Bronze, cast	456.33	0.0077861	516.31	30

CONCLUSION:

• From the above tabular data, we can see the stress is more in cast steel material comparitievely
• Total deformation is same in all the cases
• Even in stress intensity cast steel has the higher value
• Stress intensity describes the stress state at a crack tip, is related to the rate of crack growth and used to establish failure criteria due to fracture
• By taking Factor of safety into consideration, we could tell cast iron can perform better than other two