Spur Gear FEA using ANSYS Workbench with Three Different Materials

  • Objectives: To analyze Spur Gear with Three Different Materials

 

  • Geometrical Design:

Here in this project we are simulating simple Spur Gear, have a look at the geometry; 

  • Material Properties:

We will take three materials into consideration, here are the properties;

 

 

  • Problem Statement:

Spur Gear will be analyzed using ANSYS, Joint Load will be provided to extract the results.

  • Mesh Criterion:

Type of Elements: Automatic Meshing (Tet and Hex Mesh)

Element Size: 1 mm

Material 1: Cast Iron (Ductile)

 

Material 2: Cast Steel

 

Material 3: Cast Bronze

 

  • Boundary Conditions:

There are two gears in analysis named as Left Gear and Right Gear, Joint Contacts applied to both the gears, for analysis we have kept 6 steps, Left Gear Rotated in each step 30 Degrees and Right Gear is constrained with 10 N loads in 6 Steps.  

Material 1: Cast Iron (Ductile)

 

Material 2: Cast Steel

 

Material 3: Cast Bronze

 

 

  • Post Processing:

Spur Gear Analyzed with 3 different materials named as Cast Iron (Ductile), Cast Steel and Cast Bronze, we have looked at three major aspects such as Total Deformation, Equivalent Elastic Strain and Equivalent Stress.

Here it is a quick overview in below-given images;

 

Material 1: Cast Iron (Ductile)

Total Deformation:

 

Equivalent Elastic Strain:

 

Equivalent Stress:

 

Video Link:

Spur Gear FEA using ANSYS | Cast Iron (Ductile)

 

 

 

Material 2: Cast Steel

Total Deformation:

 

Equivalent Elastic Strain:

 

Equivalent Stress:

 

Video Link:

Spur Gear FEA using ANSYS | Cast Steel

 

Material 3: Cast Bronze

Total Deformation:

 

Equivalent Elastic Strain:

 

Equivalent Stress:

 

Video Link:

Spur Gear FEA using ANSYS | Cast Bronze

 

 

Post Process Results Summary;

 

  • Results and Conclusion:

 

  1. Total Deformation is comparatively same in all materials.
  2. Equivalent Elastic Strain is a bit higher in Cast Bronze as compared to other two materials
  3. Equivalent Stress is very much lower in Cast Bronze as compared to other materials.

 

After analysing all the parameters, we can see that Cast Bronze material is best suitable for application if we follow stress only as it is having fewer stress values as compared to others. But there is a significant change in density as well if we select this for application the overall weight of components may increase. 

Now let’s focus on one more import term Stress Intensity!

 

What is Stress Intensity?

Stress intensity can be defined as the theory of mechanics to study stress at the tip of cracks which is developed by the applied load. It is widely used for brittle materials and Cast Materials mostly follows Brittle behavior.

When the load is applied, stress generates due to that there is a possibility of crack generation in component. This theory is used to determine the area at which crack will generate. Stress intensity also depends on the type of geometry and loading conditions as well.

Formula for Stress Intensity Factor K = `sigma` `root``pi` `a`

Where  `sigma` = Max Generated Stress and `a`= total width of crack.

 

Now if we consider these phenomena for our project the value of stress intensity for CI Ductile is 147 Mpa which is very less or say half of its Tensile Yield strength, that means if the crack generates in CI Ductile, it will slowly increase it size but still component will keep on running in its application until total rupture takes place.

 

If we consider all the practical aspects of the project we can clearly see that CI Ductile is the best suitable for application as its stress is higher but its yield strength is also higher and it will be in operation until final rupture.


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