Week 2 Bevel Gear Challenge

Aim :

Aim of this challenge is learning about Grid dependency andPerform a grid dependency test for the Bevel gear simulation for mesh sizes of 6,5 and 4 mm

Grid Dependency:

convergence of grid dependence is the terminology used to characterize results improvement by successively using smaller mesh sizes.With decreasing the mesh sizes we will get Accurate results .

The best decision should be drawn to a calculation when the grid convergence becomes finer. With the grid getting refined and the time phase completed, spatial and temporal discrete error were reduced, asymptotically zero should approach respectively, excluding the system roundoff error.

The Grid Dependency Test is used in high-stress areas to predict accurately the results. This can be accomplished by adjusting the size of the mesh in some areas before the final results are verified.

To solve this challenge step by step procedure is

Geometry Cleanup:

In this step we import the given model and do the geometry cleanup if required . here we done the removwd some solid part from given bevel gear model .

Fig 1: Bevel Gear Geometry

Providing Contacts :

Select the contacting tooth faces of small gear and big gear total 40 contact tooths as frictional contact provide the behaviour as symetry.

Fig 2: Contacts of Bevel Gear Fig 3 : Frictional contact

Contact Joints :

Provide the Contact type is Body to Ground and revolute joint for the revolving the joint around the Z-axis as shown in Fig.

Fig 4 : Revolute Joint for small gear Fig 5 : Revolute Joint for Big Gear

Mesh and Face Mesh Generaion :

mesh for given geometry is 4mm and for get good results at contact 40 faces will provide the 1.75mm meshing size .

Fig 6 : for Face mesh selected faces Fig 7 : 4mm Mesh generated

Fig 8 : Total no.of Nodes and Elements statistics for 4MM ,5MM, 6MM mesh

Providing Load :

Moment load :

For solution total Analysis taken as 6 load steps each step taken as 100 N-MM

Fig 9: Moment for Big Gear

Fig 10 : Graph and tabular Data

Rotation Moment :

Total Rotational angle 120 angle diveded to 6 steps each step increament to 20 degree rotation .

Fig 11 : Rotational angle for small gear

Fig 12 : Graph and tabular data for rotation

Similarlly do the same steps for the remaining mesh element sizes those are 5MM and 6MM mesh sizes also

Solution :

For solutions find the Equivalent Stress,Equivalent Strain, Total deformation for different Mesh Sizes

A ) Equivalent Stress :

Fig 13 :MAX & MIN Equivalent stress for 4mm mesh

Fig14 :Equivalent Stress Table

Fig 15 : Graph and table for Equivalent stress for 4mm mesh

Fig 14 :MAX & MIN Equivalent stress for 5mm mesh

Fig 15:MAX & MIN Equivalent stress for 6mm mesh

B ) Total Deformation :

Fig 16 : Total Deformation Max & Min values for 4mm mesh

Fig 17 : Deformation Graph and Table

Fig 17 : Total Deformation Max & Min values for 5mm mesh

Fig 18 : Total Deformation Max & Min values for 6mm mesh

C ) Equivalent Elastic strain :

Fig 19 : Equivalent Elastic strain for 4mm mesh

Fig 20 : Equivalent Elastic strain Graph and Table

Fig 20 : Equivalent Elastic strain for 5mm mesh

Fig 21 : Equivalent Elastic strain for 6mm mesh

Comparing the all the above results

Mesh size	No.of Nodes	No.of elements	stress maximum(Mpa)	Stress Minimum (Mpa)	Strain Maximum	Strain Minmum	Deformation Maximum(mm)	Deformation Minimum(mm)
4mm	24060	12886	5.5098	2.0663e-8	3.512e-5	1.7.48e-13	47.873	21.651
5mm	23322	12485	4.059	2.1242e-7	2.7681e-5	3.0141e-12	47.873	21.651
6mm	23195	12406	3.2337	1.7649e-8	2.2745e-5	2.1817e-13	47.873	21.651

Conclusion :

From the above table it was very clear about the Grid dependency concept that is results are very accurate for minimum mesh size if we increase the mesh size then the result values different . For deformation it will not work but forthe stress and strain values are different when compare the mesh sizes changes .