Transient Structural Analysis on the Worm Gear

Transient Structural Analysis on the Worm Gear

Aim :

• To perform Transient Structural Analysis on the Worm Gear.

Objective :

• To define appropriate materials for the Worm Gear Model.
• To define connections between them.
• To perform mesh on the Worm Gear Model.
• To define appropriate Boundary Conditions to the Model.
• To request outputs for Total Deformation, Von-Mises Stress, Equivalent Elastic Strain.

Figure 1-Worm Gear Animation.

Procedure :

Phase 1- Material Set-Up :

• To set up the material for the Worm Gear Model. First, drag and drop the transient structural analysis workspace into the project schematic from the analysis system. This is shown in below Figure 2.

Figure 2-Ansys Workbench Workspace.

• After deploying the transient structural analysis system in the project schematic workspace.
• Define the Engineering Data and geometry, To define the Geometry and Engineering Data, Right Click on the Engineering Data and click to edit, it will take to the Engineering Tab.
• There Right Click on the Material Tab, A window will Pop-Up stating Engineering data sources.
• Click on the Engineering Data Sources, There go and select the material to define the engineering data. This is shown in Figure 3,4,5.

Figure 3-Right Click on the Engineering Data.

Figure 4-Right Click on the Material Tab.

Figure 5-Select the Structural Steel as Material to define the Model.

Phase 2-Geometry Set-Up :

• Next set up the geometry. To set up the geometry, Right-Click on the Geometry option >> Import Geometry. This is shown in below Figure 6.

Figure 6-Importing Geometry.

Figure 7-Selecting the Geometry to Import.

• Next double click on the geometry to check, Whether the model imported, is Worm Gear Model or not. Space Claim Workspace will open. The model will be imported in the space claim, Which is shown in below Figure 8.

Figure 8-Worm Gear Model in the Space Claim.

• Due to ANSYS Student Edition, We have to cut out half of the gear, Which is shown in below Figure 12.
• To cut, First, we have to define a plane, To define a Plane, Go to Design Tab >> Plane >> Select Y-Axis, Which is shown in below Figure 9.

Figure 9-Define a Plane.

• Next, we have to split the body, To split, Go to Design Tab >> Split Body >> Select the Body >> Select the Plane, Which is shown in below Figure 10.

Figure 10-Split the Body.

Figure 11-Delete the Body.

Figure 12-Final Body.

Phase 3-Model Set-Up :

• Next, define the model, Double click on the model, The Mechanical Workspace will open, There go and define the material, set up the load case for the model.
• The Model loaded in the mechanical workspace is shown in below Figure 13.

Figure 13-Model Loaded in Mechanical Workspace.

3:1 Assign Material :

• Next, define the material as Structural Steel for the whole Worm Gear Model which is shown in below Figure 14.
• To assign a material, Click on the Geometry >> Select all the Geometries of Worm Gear Model >> Parameter Window >> Assignment >>Structural Steel.
• The mechanical properties of the material are shown in below Figure 15.

Figure 14-Assign Material to the Worm Gear Model.

Figure 15-Mechanical Properties of Structural Steel.

3:2 Define Connections :

• For this Worm Gear Model, We have to Create Frictionless and two Joint Connections.

1) Frictionless Connection :

• Select the worm as contact face for the contact body and select the worm gear as contact face for the target body which is shown in below Figure 16.
• Type of Contact-Frictionless
• Keep other parameters as default, What is it.

Figure 16-Defined Frictionless Connection.

2) Revolute Joint for Gear :

• Select the inner face of the gear to define the revolute joint for the gear, Which is shown in below Figure 17.

Figure 17-Defined Revolute Joint for the Gear.

3) Revolute Joint forWorm :

• Similarly select the inner face of the worm to define the revolute joint for the worm, Which is shown in below Figure 18.

Figure 18-Defined Revolute Joint for the Worm.

3:3 Meshing :

• After defining the connections, We have to define mesh for the Worm Gear Model.
• Mesh the model with default element size with tetrahedral elements, Which is shown in below Figure 19.

Figure 19-Defined Mesh for the Worm Gear Model.

3:4 Analysis Settings :

• Here for this Worm gear Model, We are given 15 steps to run the simulation.

1) Time-Step-1 :

• The Initial Time-Step-0.2 sec
• The Minimum Time-Step- 0.2 sec
• The Maximum Time-Step-0.5 sec
• Weak Springs-Program Controlled
• Large Deflection-ON
• Output Controls-Switch Yes to all parameters except the Contact Miscellaneous.

Figure 20-Analysis Settings for Step-1.

2) Time Steps 2 - 15 :

• Carry Over time step-ON
• The Minimum Time-Step-0.2 sec
• The Maximum Time-Step-0.5 sec
• Keep other parameters and options as it is the default.

Figure 21-Analysis Settings for Step 2-15.

3:5 Boundary Conditions :

• After giving some parameters in the analysis settings, We have to give boundary conditions.
• Here we have to create only one boundary condition, Joint Rotation.
• To give Joint Rotation, Right Click on the Static Structural >> Insert >> Joint Rotation. This is shown in below Figure 22.

1) Joint Rotation :

• Select the Revolute-Ground to Worm for the type of joint.
• Select Rotational for the type of definition.
• The Shaft with Gear should rotate from 0 degrees to 750 degrees with an equal interval of 15 steps.

Figure 22-Defined Rotational Boundary Condition.

Phase 4-Request for the Outputs :

• Here we have to request outputs for the VonMisses Stress, Strain, and for Total Deformation.
• To request Output for Stress,Right Click on the Solution >> Insert >> Stress >> Equivalent Von Misses Stress.
• To request Output for Strain,Right Click on the Solution >> Insert >> Strain >> Equivalent Von Misses Strain.
• To request Output for Total Deformation,Right Click on the Solution >> Insert >> Deformation >> Total Deformation.
• This is shown in below Figure 23.

Figure 23-Requesting Outputs for the Stress, Strain, and Deformation.

• Next request output for the contact.
• To request Contact Tool >> Right Click on the Solution >> Insert >> Contact Tool >> Pressure >> Status,Which is shown in below Figures 24 and 25.

Figure 24-Requesting Output for Contact.

Figure 25-Requesting Outputs for Contact Tool.

• Similarly request the output for the probe.
• The Output requested for the Worm Gear Model is shown in Figure 26.
• After requesting all the outputs, Run the Simulation.

Figure 26-Required Outputs Requested.

• To run the simulation, Right Click on the Solution >> Solve. This is shown in below Figure 27.

Figure 27-Solve all the Outputs Requested.

• After solving the outputs requested, the simulation results for all three cases are shown below Figures.

Equivalent Von Misses Stress :

Figure 28-Equivalent Von-Misses Stress.

Figure 29-Equivalent Von-Misses Stress Simulation Animation.

Equivalent Elastic Strain :

Figure 30-Equivalent Elastic Strain.

Figure 31-Equivalent Elastic Strain Simulation Animation

Total Deformation :

Figure 32-Total Deformation.

Figure 33-Total Deformation Simulation Animation.

Results :

Cases	Equivalent Von-Misses Stress (MPa)		Equivalent Elastic Strain (mm/mm )		Total Deformation (mm)
	Max.	Min.	Max.	Min.	Max.	Min.
Case-1	1002.6 MPa	4.0628e-007 MPa	5.3381e-003 mm/mm	3.1666e-012 mm/mm	7.2612 mm	1.0671 mm

Table-1

Figure 34-Maximum Stresses at Tooth Contact Region.