Computational approach to contact fatigue damage initiation analysis of gear teeth flanks

Abstract

The paper describes a general computational model for the simulation of contact fatigue-damage initiation in the contact area of meshing gears. The model considers the continuum mechanics approach, where the use of homogenous and elastic material is assumed. The stress field in the contact area and the relationship between the cyclic contact loading conditions and observed contact points on the tooth flank are simulated with moving Hertzian contact pressure in the framework of the finite element method analysis. An equivalent model of Hertzian contact between two cylinders is used for evaluating contact conditions at the major point of contact of meshing gears. For the purpose of fatigue-damage analysis, the model, which is used for prediction of the number of loading cycles required for initial fatigue damage to appear, is based on the Coffin-Manson relationship between deformations and loading cycles. On the basis of computational results, and with consideration of some particular geometrical and material parameters, the initiation life of contacting spur gears in regard to contact fatigue damage can be estimated.

Multiscale modeling and simulation of rolling contact fatigue

“…The full contact width along the face width (Z direction) was 28 mm, the Hertzian contact load width was 2.39 mm and the sample pressure P 0 was 1550 M P a [73,76]. an initial crack.…”

“…In this case, modeling the occurrence of defects (crack initiation) and the crack propagation are important [76] to accurately predict the service life. Secondly, a defect such as a crack is detected during periodic inspection.…”

“…Shear subsurface stresses due to contact loading cause a substantial dislocation motion, which can initiate fatigue cracking [73,76]. Sraml et.…”

“…Sraml et. al [76] developed a general computational model for the simulation of contact fatigue crack initiation in the gear tooth. They used damage mechanics to model fatigue crack initiation in a two-dimensional model.…”

Investigation into initiation and propagation of cracks in the coated surfaces of spur gears with submodelling and irreversible cohesive-zone modelling techniques

“…Thin hard coatings have positive influences on the fatigue and corrosion fatigue behaviours of the mechanical components, which justifies their uses in some critical systems such as automotive systems [2] and aeronautic systems [3]. Prior to the initiation of the research reported in this paper, it was found that there was a need to develop a more reliable, theoretical and numerical model for the analysis of coating surfaces in the gears, although some effort had been made on the analysis of the fatigue damages of the coated gears [4,5]. To-date, analysis of the coatings in engineering surfaces still largely relies on the uses of empirical formulas or is based on experience.…”