A simulation of the rolling contact fatigue strength of a traction drive element was proposed. The simulation can account for both the distribution of sizes of inclusions in the element material and the influence of traction forces at the element surface. The shear strength of the matrix structure surrounding an inclusion was estimated with an equation. The hardness distribution and the Weibull distribution of inclusion dimensions, which were necessary parameters to calculate the rolling contact fatigue strength, were determined by observation of an actual test specimen. And the rolling contact fatigue strength was compared with the distribution of shear stresses in a roller affected by traction forces. A simulation assuming the same traction coefficient as that in the experiment predicted a rolling contact fatigue strength of 810 MPa with a standard deviation of 39.2 MPa, which differed from the experimental value by only 2.5%. Simulations of the rolling contact fatigue strength were then carried out while varying the traction coefficient. The contact force resulting in failure was observed to fall as the traction coefficient increased and the torque capacity increased. Thus, the torque capacity increases with the traction coefficient, regardless of changes in the rolling contact fatigue strength.
The mixed and fluid film lubrication characteristics of plain journal bearings with shape changed by wear are numerically examined. A mixed lubrication model that employs both of the asperity-contact mechanism proposed by Greenwood and Williamson and the average flow model proposed by Patir and Cheng includes the effects of adsorbed film and elastic deformation is applied. Considering roughness interaction, the effects of the dent depth and operating conditions on the loci of the journal center, the asperity-contact and hydrodynamic fluid pressures, friction, and leakage are discussed. The following conclusions are drawn. In the mixed lubrication regime, the dent of the bearing noticeably influences the contact and fluid pressures. For smaller dents, the contact pressure and frictional coefficient reduce. In mixed and fluid film lubrication regimes, the pressure and coefficient increase for larger dents. Furthermore, as the dent increases and the Sommerfeld number decreases, the flow rate continuously increases.
This paper deals with an experimental evaluation of bending fatigue strength for austempered ductile iron (ADI) spur gears. The module is 2.5 and the number of teeth is 26 in the test gears. The material of the test gears corresponds to Japan Industrial Standard (JIS) FCAD1100-15. Some gears are processed by one of two types of fine particle bombarding (FPB). The surface roughness is slightly increased by FPB. The obtained strengths are 623 MPa for the as-austempered gears, and 1011 and 1085 MPa for the gears after FPB. The strength is expressed by the fillet stress level, which is calculated by FEM. The strength of a gear with the same dimensions made of carburized SCr420H alloy steel is 1205 MPa, and the strength of the ADI gear is approximately half that of the carburized steel gear. The FPB process has a significant effect on the ADI gear, improving its strength by 62-74%.
This paper deals with an experimental evaluation of bending fatigue strengths for hobbed, forged, sintered and austempered ductile iron (ADI) spur gears. The module is 2.5 and the number of teeth is 26 in the test gears. The materials of the test gears are SCr420H for hobbed and forged gears, prealloyed powder metal with 1.5 wt.% Mo for sintered gears, and FCAD 1100-15 for ADI gears. All gears except ADI gears were carburized. The pulsator bending fatigue tests were carried out for the test gears. Then the relationship between the strength and the manufacturing cost is obtained. The forged gear has the high strength of 3% and low cost compared with the hobbed gear. It is the best among the four gears. The sintered and ADI gears have approximately half the strength and cost of the hobbed gear. These gears are effective when cost is a high priority. In the progress of the fatigue tests, comparisons of strength among gears having different tooth-root forms were needed. The nominal stress obtained from actual measured profile data using a noncontact-type measuring machine is suitable for comparing the fatigue strength in gears having different root forms.
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