Worm Gear Challenge

• Objectives: To analyze Worm and Gear Assembly for Stress Analysis.

• Geometrical Design:

For this project we have two parts in assembly named as Worm & Gear.

This is how full geometry looks like,

For the sake of FE Analysis we will look for stress only in half portion of gear, this will lead to less computational time, this is how an updated geometry looks like;

• Material Properties:

In this analysis we will keep Structural Steel as default material for both the parts, here its mechanical properties;

• Problem Statement:

We have an assembly of two parts Worm & Gear, in which Gear will be applied with rotational joint and joint load, will be applied to Worm. Transient Structural Analysis Module of ANSYS Workbench is used. As the worm will rotate, gear will rotate and we will look for various results such as Deformation, Strain & Stress.

• Mesh Criterion:

Type of Elements: Tet & Hex Elements (Automatic Meshing)

Size of Elements: Default

Adaptive Sizing: Yes

Smoothing: Medium

Mesh Model:

• Boundary Condition:

Frictionless Contact is kept between Worm & Gear; Various Teeth are in contact with each other can be seen from image below;

Contact:

Two Revolute Joints applied to assembly, both are kept in Body – Ground Condition.

Joints:

• Loading and Analysis Settings:

For Loading the Worm is applied with Joint Rotation (Revolute- Ground to Worm), in which total 18 steps applied for analysis, each step applied 100 Degree of rotation in each step.

No of Steps: 18

Carry Over Time Step: ON

Initial Time Step: 0.2 s

Minimum Time Step: 0.2 s

Maximum Time Step: 0.5 s

Large Deflection: ON

Analysis Settings:

Loading:

• Post Processing:

Total Deformation:

Equivalent Elastic Strain:

Equivalent Stress:

Post Process Results Summary;