ME-411 Introduction to Finite Element Analysis
Lab Report # 4
Static Structural Analysis of Sprocket
Course Instructor: Sir Raja Amer
Lab Instructor: Sir Omer Abraiz
Student Name: Maria Imran
Degree/ Syndicate: 45 – ME – C
Introduction
A sprocket is a profiled, toothed wheel designed to transmit rotary motion through a
chain. Sprockets are commonly used in bicycles, motorcycles, and industrial conveyor
systems. Unlike gears, sprockets do not mesh directly with each other; instead, motion
is transferred via a chain linking the sprockets on different shafts.
In this study, a static structural analysis of a sprocket was performed using ANSYS
Workbench to evaluate its mechanical performance under applied loads. The sprocket
material was structural steel with a Young’s modulus of 2 × 10¹¹ Pa and a Poisson’s
ratio of 0.3.
Geometry and Model Description
Meshing:
Boundary Conditions:
Boundary conditions included a fixed support on half of the outer rim and an applied
moment of 39 Nm on the inner rim. The mesh was generated using the default settings
with adaptive sizing and a resolution of 4. Named selections were created for the outer
and inner rims, and boundary conditions were applied using the scoping method.
Post-Processing:
Results analyzed include equivalent (von Mises) stress, maximum shear stress,
and total deformation, visualized using auto scale, true scale, and without the
wireframe view for better interpretation of deformation and stress distribution.
Equivalent Stress (True Scale):
It shows true deformation rather than an exaggerated one as shown by Auto scale.
True Scale view without wireframe:
Total Deformation (True Scale):
True Scale view without wireframe:
Static Structural Analysis of a Gear
Introduction:
In this study, a 3D finite element analysis (FEA) of a spur gear pair is performed to
evaluate stress distribution and deformation under applied torque. Proper boundary
conditions and contact definitions are applied to simulate realistic gear interaction.
Geometry:
First, the surface of gear is made by using “Surfaces from faces” from a 3D gear. A
spur gear model was created and relocated using the Body Transformation→
Translate command in ANSYS Design Modeler. The gear was translated by a
distance of 5 inches from its original position. The option “Preserve Bodies = Yes”
was selected to create a duplicate of the original gear, resulting in suitable meshing.
Before opening the Mechanical module, a 2D structural analysis system was
selected.
Meshing:
Boundary Conditions:
The inner rim of the lower (original) gear was assigned to Fixed Support, restricting all
translational and rotational degrees of freedom. The inner rim of the upper gear was
assigned to a Frictionless Support, which restricts motion in the normal direction
while allowing tangential movement.
A clockwise torque of −5000 lbf·in was applied to the upper gear to simulate power
transmission. To ensure proper interaction between the two gears, contact was
defined under the Connections branch, and the “Add to Touch” interface treatment
was applied.
Solution Results:
Equivalent Stress:
Penetration due to Auto scale view:
Using True scale:
Total Deformation: