The basic steps of face contact analysis using the finite element method are as follows: 1) establishing a three-dimensional solid model, dividing the mesh; 2) identifying contact pairs; 3) defining rigid and flexible contact faces; 4) setting unit keywords and real constants; 5) Define/control the motion of the rigid target surface; 6) Given the boundary conditions; 7) Define the solution options and load steps; 8) Solve the values; 9) View the calculation results.
The solid model gives the basic parameters of the helical gear and establishes a three-dimensional accurate model of the helical gear on Pro/E2001. Then install the two gears in the Pro/E Assembly file and set the center distance to 129mm. Since there is no contact deformation at this time, you can check whether there is interference between the two gears through Analysis/ModelAnalysis/GlobalInterference.
Unit selection and mesh division The model is poured into ANSYS. The large gear is divided into units by SOLID45 unit. The contact surface of the large gear is divided by the contact unit CON-TA173. The meshing surface of the small gear is divided by the target unit TARGE170. The number of units in the model is as shown.
Number of Unit Types Number of Unit Types The Solid4586848CONTA174180TARGE170439CONTA174 unit is a 3-dimensional 8-node high-order quadrilateral element that, as shown, can be applied to three-dimensional structures or coupled field contact analysis, which is attached to a 3D shell or solid element surface, and The connected cell surfaces have the same geometric properties. CONTA174, andCONTA175 units are connected to represent different 3D target surfaces. For a complex, arbitrarily shaped target surface, a triangular face should be used to model it. TARGE170 only needs to set the real constants R1 and R2 to reduce the number of cells, saving calculation time. In the gear tooth meshing area, the mesh division is dense, while in the far away meshing area, the mesh division is relatively small. The finite element obtained after meshing is as shown.
Applying a constraint constrains the nodes on the surface of the gear mounting hole to make it only have a degree of freedom of rotation about the central axis of the gear. ANSYS automatically and fully constrains the target unit to fully constrain the surface of the large gear mounting hole.
Contact Stress Analysis Contact is a non-linear behavior. In ANSYS, the face-to-surface contact unit uses the GAUSS integration point as the default value of the contact checkpoint. It produces more accurate results than the Newton-Cotes/robatto node integral term.
: TARGE170 unit: Gear meshing model after grid First step, material property setting: elastic modulus: 210Gpa; Poisson's ratio: 03; density: 7.8103kg/m3. In addition, the value of the real constant should be determined according to the specific environment. For example, for the normal contact stiffness factor FKN, since the gear deformation is mainly curved, the value is recommended to be 0.0101, where 001 is taken, and the rest of the parameters are taken as default values. The second step, loading: the output torque of the third stage deceleration is T3=2670.483Nm, and the circumferential torque is returned to the gear according to the transmission torque obtained in the analytical analysis.
The third step, solving: For nonlinear problems, ANSYS's equation solver uses a linear approximation with correction, which divides the load into a series of load vectors, and applies the finite element model of the boundary conditions and loads in several load steps. Or apply within a few substeps of a load step. The contact analysis obtained the stress cloud diagram as shown in the figure, the stress unit is MPa), and is equivalent by the third strength theory. The maximum stress value of gear 1 is 1030.00 MPa, and the maximum stress value of gear 2 is 555.817 MPa.
Analysis and conclusion After calculation and analysis, the stress of the root of the gear in the low-speed gear pair is high-force zone during the meshing process, but there is also a stress concentration phenomenon in the top of the tooth tip. This may be the hammer of the tower at work interruption. one of the reasons.

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