Week 2 Bevel Gear Challenge

Aim : The aim of this week challenge is to perform a grid dependency test on bevel gears for various mesh sizes and explain the result for various stress and strain plots.

procedure:

grid dependency test

step 1: open the ansys workbench module and select the static structural analysis

step 2: Right click the geometry tab and select import geometry-->browse-->select the file-->open

step 3: now click the geometry tab and select edit geometry in space claim option

step 4: Now remove the material near the center hole of the gear to optimize the design.

step 5: Now assign the material structural steel to both the gears.

step 6: Now change the mesh size of the element to 6mm and mesh the model

step 7: Now create the contact between two contact

step8: Now create a revolute joint for both the gears

step 9: Now change the analysis setting and on the large deflection

step 10: Now run the simulation.

step 11: Now include the total deformation, equivalent stress and stress intensity in output files

step 12: Now repeat the simulation by changing the mesh size to 5mm and 4mm

step 13: compare the result plot and give a detailed explanation

1. 6mm mesh

equivalent stress

total deformation

2. 5mm mesh

equivalent stress

total deformation

3. 4mm mesh

equivalent stress

total deformation

Conclusion:

equivalent stress in (Mpa) total deformation in (mm)

Min Max Min Max

6mm mesh 4.71E-0.5 256.69 25 64.52

5mm mesh 3.82E-0.5 188.65 25 64.52

4mm mesh 7.60E-0.5 260.48 25 68.82

Based on the result we got from the above simulation the total deformation is same for 6mm and 5mm mesh and there is a slight increase in 4mm mesh. The equivalent stress for the 6mm and 4mm mesh are almost similar but there is a drastic decrease in 5mm mesh which may be due to the element formulation at that point. When I tried with 4.8mm the equivalent were about 266Mpa from the range of 4.8 to 4.9mm the stress are lowering to 188Mpa.