Week 2 Bevel Gear Challenge

OBJECTIVE:

The bevel gear has to be analyzed for equivalent stress, strain and Total deformation. While performing this analysis grid dependency test is also carried out with it. Three sized meshes are verified for grid dependency viz. 6mm,5mm &4.5mm.  

GRID DEPENDENCY TEST:

Another name for grid dependency test is “mesh refinement”. In this technique initially the results are evaluated using a coarse mesh of bigger size then the value of same output parameters is compared with the models having a mesh size a bit smaller. This size of the mesh is reduced until the results value doesn’t change anymore at this point the values obtained could be considered as independent of the mesh size. This entire process is called as grid dependency test.  

ADVANTAGES:

The main advantage of grid dependency test is the process of the solving is fastened a bit. As we don’t have to go for very fine meshes which in turn increases the solving time.

CASE-1 : MESH SIZE= 4mm:

DEFORMATION= 47.838 mm

STRAIN = 0.00203

STRESS = 467 MPa

CASE-2: MESH = 5mm

                                                                                                         

                                                                                                          Strain= 0.00199

 deformation=0.00199                                                                     stress= 369 MPa

CASE-3: MESH = 6mm

 

                                                                                                           Strain = 0.00225

Stress= 467 MPa                                                                             deformation= 47.898 mm

 

CASE AND SETUP

MODEL : The model is imported in the space claim environment directly for mesh generation and set up.

MATERIAL: The material used is the structural steel which is present by default in the workbench environment.

CONNECTION: As this is a gear engagement problem the connection has to be defined including two parameters i.e., contact & joints.                                                                                             

           Contacts: The gear tooth surfaces are                                               Joints: The gear & pinion are

                              Defined as contact points.                                                             Given with revolute                    

                             In gear there are 16 faces&                                                             joint with respect to

                             In pinion there are 24 faces                                                             ground.

JOINT LOAD: The gear is given a moment of 1000 N-mm. While the pinion is given with rotation till 120 degree. While giving this joint load both the gear & pinion motion direction are opposite which is an appropriate simulation.

MESH: In total there are three different mesh sizes are used 4mm,5mm& 6mm.For the result comparison.

SOLUTION: The model is analyzed for three parameters viz. von misses stress, equivalent strain,& deformation

RESULT:

MESH SIZE	STRESS	STRAIN	DEFORMATION
6 mm	467 Mpa	0.00225	47.898 mm
5mm	369 Mpa	0.00199	47.898 mm
4 mm	372 Mpa	0.00203	47.898 mm