General Mechanical

General Mechanical

Spur gear stress analysis


    • fab88

      Dear all,

      I would like to perform a 2d structural analysis of spur gears.

      However, when I try to do a joint load. I don't find a way to add a joint.

      In 2D analysis, what are the options we have to add a joint?

      I am able to do this in 3D but not in 2D.

      Thank you in advance.


    • Florian.CHANCEL

      I have done this type of calculation before, with simple gear or planetary gear.

      If you just want a simple rotation, you can add a remote displacement in the boundary conditions, and release the rotation DOF.

      If you want a coupled rotation for instance like the satellite displacement, it's more complexe :

      Firstly, I defined Remote points of the satellite's center

      And I defined their DOF

      Secondly, I defined a "bearing remote point" of the remote point created before

      And I defined their DOF

      In a third step, I defined a distant point corresponding to the center of rotation of the planet holder

      And I defined its DOF

      And finaly, I defined a remote displacement of this last remote point, in the boundary conditions

      To controle the rotation DOF


      Maybe, this process could have been less complex.

      I hope this will help you,


      Florian C.

    • fab88

      Thank you for Florian,

      I'm working on a simple rotation.

      I'm going to try as you suggested.

      I will come back with my results.

      Thank you again.

    • fab88

      Hello, Florian!

      I have managed to successfully run the 2D model.


      Thank you for your guidance.

      Now, I am trying to reduce the computation time and improve the accuracy by using a simulating frictional model of the gear instead of the full gear.

      However, it seems my boundary conditions are giving me trouble.

      Do you have any guidance on how I should proceed?

      I am attaching a link to my archive file ( ) for your review.

      Thank you

    • Florian.CHANCEL

      I cannot open you project.
      I think you sent me the wrong file. It's not the archive file.
      Can you try again ?

      The frictional contact between your teeth must have a "close statut" at the beginning of the calculation otherwise it will not converge.

      I don't see your mesh, but you can compute an inflation to have accurate results.

    • fab88


      I come to realize that I attached the wrong file.

      The initial contact status is closed.

      Here is the correct file.

      Thank you.

    • Florian.CHANCEL

      I cannot open your file because it's an older version than I have(I use 2021R1).

      Can-you try to explain your boundary conditions, your load cases, your mesh and connexion details ?

    • fab88

      Actually, I had forgotten to apply a remote displacement on the driven gear. But now, it is working.

      Here are my BCs.

      Also, I had to include in weak springs to avoid rigid body motion. 

      Now, I am facing another problem. When I am trying to allow full rotation (360) of the cut gears, the solution fails to solve. Let's say, I want 10 revolutions.


      I mean after this time.

      What can I do?


    • Florian.CHANCEL

      Ok, you have to set up some steps to help the static calculation

      Step 1 : You lock (0°) the rotation of the left pinion, and apply the torque on the right pinion.

      Step 2 : you rotate the left pinion (for example 10°) => In this step, you have to set up sub step every 1°(or more) => Substeps are the key to the convergence. Your calculation have to stay in static, if the rotation gap is to big, calculation will fail

      Advice 1 : You should fixe your remote point on the two cut edges of your pinion and set up the rigid behavior 

      Advice 2 : turn on "large displacement"

      Advice 3 : Weak springs are not a problem, you just have to check if the reaction forces are near 0 N after your calculation.

      Advice 4 : 360° is not useful, I think juste a rotation on 3 teeth are good enough to capture all results.

      Can you show your mesh, can you send me CAD file in .step ?

      Can you show me the parameters of your frictionnal contact ?


    • Florian.CHANCEL

      Ok, I also understood something thanks to your pictures.

      The rotation of your left pinion is counterclockwise => Therefore, after 1.0463 sec, as you can see, you have the last contact point on the last teeth. So there is no anymore teeth to keep the input torque ! I think your calculation fail because of this.

      ou cannot have 360° or 10 revolutions because you have only 1/4 of your pinion.


    • fab88

      The project that I am working on consists of calculating displacements/ stresses and temperatures. It is a transient thermomechanical analysis. Therefore, I need to have more revolutions to get to a stable temperature. Young's modulus is a function of temperature. In order to reduce the computation time, I cut the gears into quarters.

      The calculations I was doing are preliminary (Transient structural analysis)

      The torque on the left gear (driven gear) is an output torque.

      The remote displacement on the pinion is equivalent to a constant angular velocity.

      Here are my frictional contact details

      Here is my CAD file

      Thank you again.

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