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Two-Stage Cast Gearbox Housing
Shaft bearing bore deflection and casing rigidity analysis under maximum transmitted gear tooth meshing loads.
Industrial gear transmission housings must maintain micrometer-level alignment of shaft centers under severe separating and tangential tooth contact forces. Excessive casing compliance alters gear mesh tooth contact patterns, provoking accelerated gear wear, vibration, and premature bearing seizure. This simulation calculates the global deformation field, bearing seat misalignments, and casting stress levels under rated full-torque power transmission.
1. Geometry & FEA Mesh
- •Grey cast iron EN-GJL-250 (СЧ-25: E = 115 GPa, ν = 0.26, tensile strength 250 MPa).
- •Cored monobloc housing geometry featuring 4 precision bearing bores for high-speed input and low-speed output shafts.
- •Reinforced wall architecture with 6 external triangular stiffening ribs, inspection port flange, and 4 thick mounting feet.
- •Tetrahedral solid mesh with 164,120 elements and 147,800 active degrees of freedom.
2. Loads & Boundary Conditions
- •Fixed displacement constraint on the bottom contact planes of the 4 foundation mounting bolt feet.
- •Input shaft bearing reaction force: 8.2 kN radial load and 3.1 kN axial thrust applied to bearing bores #1 and #2.
- •Output shaft bearing reaction force: 24.6 kN high radial separating force applied across bearing bores #3 and #4.
3. Simulation Results & Findings
- ✓Peak von Mises stress σ_vm = 13.5 MPa situated at the internal corner blend between the output bearing boss and the sidewall.
- ✓Maximum displacement magnitude |u| = 0.030 mm at the upper inspection aperture rim, well within allowable gear casing deflection.
- ✓Safety factor exceeds 10.0 against brittle tensile failure, guaranteeing flawless dimensional stability and long-term gear train life.
Gearbox manufacturers verify housing stiffness and bearing bore deflections within minutes using WebCAE without requiring high-end workstation licenses. Fast iterative evaluation of rib placement cuts raw material weight by up to 15% while guaranteeing silent meshing.
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