Week 2 Bevel Gear Challenge

Case Study of Stress, Strain And Deformation for the Mesh Size Of 6, 5 & 4mm Mesh.

Objective:

1) Perform a grid dependency test for the Bevel gear simulation for mesh sizes of 6,5 and 4 mm

2) Solve for Von-Mises stress, Equivalent elastic strain, and Total Deformation using the previously mentioned mesh sizes.

Grid dependency test: It is to investigate how the solution depends on the grid size by running the simulation with refined mesh that is finer the mesh, higher is the accuracy of the result but with additional cost on computation time and computational power.

Case1:

For Case 1, Static Structural Analysis is carried out on Bevel Gear. The material is Structural Steel & the Mesh Size is 6mm and the analysis is carried out on Ansys Workbench. The geometry of the model is imported on the Ansys Workbench for analysis. The Gear is first modified in the space claim and internal dia of the gear is increased.

2D Geometry is extruded in the Space Claim to get the model to be imported to the ANSYS. The Extruded model is as shown in the image below:

The properties of the material is stated below:

Density: 7850 kg/m³

Tensile Yield Strength: 2.5E+08 Pa

Tensile Ultimate Strength: 4.6E+08 Pa

Young’s Modulus: 1.2E+05

The simulation is then run with the setting and the results are then obtained.

Case 2:

For Case 2, Static Structural Analysis is carried out on Bevel Gear. The material is Structural Steel & the Mesh Size is 5mm and the analysis is carried out on Ansys Workbench.

Case 3:

For Case 3, Static Structural Analysis is carried out on Bevel Gear. The material is Structural Steel & the Mesh Size is 4mm and the analysis is carried out on Ansys Workbench.

Results:

Total deformation of the 3 cases are compared.

Time [s] Minimum [mm] Maximum [mm] Average [mm]

6. 25.933 47.92 35.929
7. 25.933 47.908 36.223
8. 25.933 47.938 36.21

Equivalent Stress of the 3 cases are compared.

Time [s] Minimum [Mpa] Maximum [Mpa] Average [Mpa]

6. 8.025e-005 258.6 7.2811
7. 6.637e-005 430.57 9.374
8. 3.2045e-005 268.41 6.3971

Equivalent Von-Mises Strain of the 3 cases are Compared.

6. 6.8287e-010 1.5092e-003 4.4365e-005
7. 3.3928e-010 2.7591e-003 6.2072e-005
8. 4.4728e-010 1.6964e-003 3.816e-005

The total deformation on the gear is as plotted and is shown on the plate below.

The Equivalent stress is plotted on the plate and is as shown below.

The Equivalent strain is plotted on the plate and is as shown below.

Conclusion:

The Analysis was run succesfully, within the limits of the academic license, the simulation for the 3 cases were examined.