Week 2 Bevel Gear Challenge

Objective: To perform a grid dependency test for the Bevel gear simulation for mesh sizes of 6 mm, 5 mm and 4 mm.

Grid dependency test is a process in which simulations are performed by gradually reducing the mesh element size until the solution converges. In other words, the process is continued until there is no further change in the solution with mesh element size reduction. Once convergence is achieved, the process is stopped as any further reduction of mesh element size just increases the computational time required to solve the problem.

Procedure:

Meshing (Gear Teeth element size 1.75 mm):

1. Mesh element size 6 mm:
2. Mesh element size 5 mm:
3. Mesh element size 4 mm:

Boundary Conditions:

Analysis:

1. Iteration 1 (Mesh element size 6 mm):
   1. Total Deformation:
   2. Equivalent Elastic Strain:
   3. Equivalent Stress: 
2. Iteration 2 (Mesh element size 5 mm)
   1. Total Deformation:
   2. Equivalent Elastic Strain:
   3. Equivalent Stress:
3. Iteration 3 (Mesh element size 4 mm)
   1. Total Deformation:
   2. Equivalent Elastic Strain:
   3. Equivalent Stress:

Result:

Iterations	Total Deformation (mm)		Equivalent Elastic Strain (mm/mm)		Equivalent Stress (MPa)
	Maximum	Minimum	Maximum	Minimum	Maximum	Minimum
Iteration 1	47.882	21.651	5.2729×10^-5	2.8919×10^-12	7.8753	3.8233×10^-7
Iteration 2	47.878	21.651	4.2831×10^-5	3.9252×10^-12	6.5084	4.0052×10^-7
Iteration 3	47.881	21.651	3.7423×10^-5	9.0326×10^-13	5.2262	6.0142×10^-8

Conclusion: The total deformation has almost converged after iteration 3. However, equivalent elastic strain and equivalent stress require more iterations for convergence.