Week 2 Bevel Gear Challenge

Objective:- compare the finite element analysis results obtained by using grid dependency test with 3 different mesh size for bevel gear and write a detailed report explaining the results obtained.

Grid dependency test:- grid dependency is for convergence that is used to described the improvements of results by using successively smaller cell sizes for the calculations. A calculation should approach the correct answer as the mesh becomes finer. To perform the test all cases should have different mesh refinement.

PROCEDURE:-

Model:-

Material:- CARBON STEELS

Carbon steels which find applications for industrial gears where high toughness combined with high strength.

Contacts: contacts has been applied as shown below

Joints:- revolute joints has been applied to both gears.

Analysis settings:-

Joint load:- joint load has been applied as shown below. For small gear-rotation

For big gear – moment:-

Case-1: mesh size 4mm: Mesh : size of element – 4mm

Face sizing: mesh face size 1.75mm applied on the faces which will come into contact.

Results:-

Equivalent stress:

Equivalent elastic strain:

Total deformation:

Using parameters set:

Check results for mesh elements of 5 and 6mm size using parameter set.

Results comparison and conclution:-

Results comparison:

mesh Total equivalent equivalent

size Deformation(mm) elastic strain stress(MPa)

min max min max min max

4 27.289 47.881 6.270E-13 4.7136E-05 1.038E-07 8.8911

5 27.289 47.881 6.186E-13 7.3521E-05 6.2703E-08 15.399

6 27.289 47.881 6.142E-13 4.8746E-05 8.4351E-08 8.3836

• Total deformation is same for all cases
• Equivalent elastic strain and equivalent elastic stress is higher in case 2 (5mm mesh element size) so element size 5mm is not consider.
• Difference in values of stress and strain for 4mm and 6mm is in decimals.
• Nodes and elements are increased due to decrease in element size and computational time and effort increased.
• So to save time and effort and as there isn’t much difference in values , I would prefer case 3 with element size 6mm.