I have created a rod-crank-gear simulation project with 2 types of simulations:
- Static Nonlinear
This was done to show the differences in model setup and the results. The complete setup can be seen below, and the project can also directly be copied for use/refinements.
The CAD model was uploaded by the user [trinityscp](https://grabcad.com/trinityscsp) on GrabCAD. The step file was downloaded and a few parts unnecessary for simulation were removed/merged.
Meshing was performed, and a coarse mesh was used. If more accurate results are needed, a mesh refinement can also be provided (eg., at the teeth, or various contacting surfaces).
The simulation was designed as a static non-linear simulation. The physical contacts were provided between the following pairs:
- Primary rod (drive shaft) and action rod (connecting rod)
- Teeth of action rod and reaction rod (rod with gears)
- Action/reaction rods and piston (ram)
- Piston with the outer box (casing)
There were 3 boundary conditions used in the dynamic simulation:
- The outer body (casing) was fixed
- All the bodies were allowed no Z - translation
- The primary rod (drive shaft) was provided with a rotation of 360 degrees
In addition, in the static simulation, an _elastic support_ boundary condition was used. This was done to ensure no rigid body motion occurs in the first steps, and results in a smooth convergence.
The simulation end result can also be seen below: