Week 2 Bevel Gear Challenge
AIM: To perform Grid Dependency test for the Bevel Gear of mesh size 6mm,5mm or 7mm.
Importing a CAD model with no errors in geometry and viewed in Spaceclaim.
- Setup for analysis:
Contact setting: Structural Steel material is choosen for Bevel gear assembly system with the contact properties of:
1)Type:Frictional contact
2)Formulation:Augumented Lagrange
3)Interface Treatment:Adjust to touch
- Joint creation:
Two body ground Revolute joint is created for two mating gears with 16 & 24 teeths.
- Meshing:
Face sizing of gear teeths of both gear at 2.00 mm, which is basically the area of contact between two mating gears in order to avoid non covergence during solution.
- Analysis setting:
Larger gear with 24 teeth is given input of 100 Nmm torque
Smaller gear with 16 teeths is given rotation in 6 steps 20 degrees each from 0 to 120 degrees.
Results:
The analysis is doen for the model above and results generated for Total deformation,Equivalent Stress & Equivalent Strain for 6mm,5mm & 4mm mesh size are shown below alongwith force convergence graph.
Case 1: 6mm Mesh Size
Total Deformation:
Equivalent Elastic Strain:
Equivalent Stress:
Case 2: 5mm Mesh size
Total Deformation:
Equivalent Elastic Strain:
Equivalent Stress:
Case 3: 4mm Mesh size
Total Deformation:
Equivalent Elastic Strain:
Equivalent Stress:
Conclusion:
Comparing the results of above three meshed models:
|
Element Size (mm) |
Max Total Deformation(mm) | Max Equivalent Elastic Strain (mm/mm) | Max Equivalent Stress(MPa) |
| 4 | 47.884 | 2.152e-005 | 3.905 |
| 5 | 47.884 | 2.1142e-005 | 3.4995 |
| 6 | 47.884 | 2.6019e-005 | 3.8627 |
Total deformation & Maximum Equivalent Strain are almost equal for all three meshed models, with decrease in mesh size there is only small changes observed in Maximum Equivalent Stress in all three models.
So we can conclude from here that mesh size of 6 mm is accurate and when we decrease mesh size there is no significant change in simulation solutions of Equivalent Stress,Equivalent Elastic Strain & Total Deformation.
Grid dependency file is attached below of varoius mesh size.