Spur gear modeling errors

  • Last Post 29 July 2019
  • Topic Is Solved
xRtC posted this 21 July 2019

Dear community,

The last couple months i tried to model a set of gears without a result.

Below you can see the procedure i followed and i have attached images for your better comprehension.

Contact formulation

  • Type:    Frictionless
  • Formulation: Augmented Lagrange
  • Interface treatment: Adjust to touch
  • Initial information about contact with contact tool: The contact status is open. This may be acceptable.


I inserted joint at each gear with joint rotation at pinion -40 degrees and joint moment at  the gear -27000N*mm.

The problems i am facing are listed below:

  • The solver engine was unable to converge on a solution for the nonlinear problem as constrained.  Please see the Troubleshooting section of the Help System for more information.
  • The unconverged solution (identified as Substep 999999) is output for analysis debug purposes. Results at this time should not be used for any other purpose.
  • One or more bodies may be underconstrained and experiencing rigid body motion. Weak springs have been added to attain a solution.  Refer to Troubleshooting in the Help System for more details.
  • The number of divisions specified is unsuitable for sweeping. Check all the edges and faces along the sweeping path.
  • The number of divisions specified for sweeping is unsuitable and has been ignored.

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xRtC posted this 21 July 2019

sweep methodjoint rotation

peteroznewman posted this 21 July 2019

Please reply with images inserted that show the geometry and the mesh on the gear teeth.

The gear teeth should be tangent, which means they would be touching and the initial contact status should be closed. What is the initial gap?

xRtC posted this 24 July 2019

 Modeling Formulation:

Initial contact status

  • Initial information
  • PenetrationGapStatus




peteroznewman posted this 24 July 2019

All the images show you have created a reasonable model except for one thing.

You have a revolute joint on one gear and the other gear should have a fixed support. The revolute joint should have a moment load. I see you have that.

What troubles me is the -30 degree rotation of a revolute. What is that?  Get rid of it.

xRtC posted this 29 July 2019


The problem was that the revolute had opposite direction on Z axis here is the results

Thank you