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Abstract:Recent studies have shown that micropitting initiated pitting appears to be the dominant metal fatigue mode in modern bearings and gears. If the formation of micropits can be controlled, the fatigue life of the bearings and gears can be readily lengthened, so the useful life of the engine or transmission can be radically extended. The lack of in-depth understanding of micropitting initiation mechanism hinders progress to control the micropitting-initiated pitting failure mode. In this study, we explore the ini… Show more
“…As revealed by various experimental observations [28][29][30], the difference of gear steel materials and the heat treatment process could generate distinguished micropitting resistances. As reported in the Reference [31], high strength austempered ductile iron gears were gradually accepted due to the low production cost, the eventual noise and vibration reduction, and the self-lubricant properties through graphite nodules, resulting in remarkable gear tooth flank capacity.…”
Section: Gear Materials and Macroscopic Geometriesmentioning
With the mounting application of carburized or case-hardening gears and higher requirements of heavy-load, high-speed in mechanical systems such as wind turbines, helicopters, ships, etc., contact fatigue issues of gears are becoming more preponderant. Recently, significant improvements have been made on the gear manufacturing process to control subsurface-initiated failures, hence, gear surface-initiated damages, such as micropitting, should be given more attention. The diversity of the influence factors, including gear materials, surface topographies, lubrication properties, working conditions, etc., are necessary to be taken into account when analyzing gear micropitting behaviors. Although remarkable developments in micropitting studies have been achieved recently by many researchers and engineers on both theoretical and experimental fields, large amounts of investigations are yet to be further launched to thoroughly understand the micropitting mechanism. This work reviews recent relevant studies on the micropitting of steel gears, especially the competitive phenomenon that occurs among several contact fatigue failure modes when considering gear tooth surface wear evolution. Meanwhile, the corresponding recent research results about gear micropitting issues obtained by the authors are also displayed for more detailed explanations.
“…As revealed by various experimental observations [28][29][30], the difference of gear steel materials and the heat treatment process could generate distinguished micropitting resistances. As reported in the Reference [31], high strength austempered ductile iron gears were gradually accepted due to the low production cost, the eventual noise and vibration reduction, and the self-lubricant properties through graphite nodules, resulting in remarkable gear tooth flank capacity.…”
Section: Gear Materials and Macroscopic Geometriesmentioning
With the mounting application of carburized or case-hardening gears and higher requirements of heavy-load, high-speed in mechanical systems such as wind turbines, helicopters, ships, etc., contact fatigue issues of gears are becoming more preponderant. Recently, significant improvements have been made on the gear manufacturing process to control subsurface-initiated failures, hence, gear surface-initiated damages, such as micropitting, should be given more attention. The diversity of the influence factors, including gear materials, surface topographies, lubrication properties, working conditions, etc., are necessary to be taken into account when analyzing gear micropitting behaviors. Although remarkable developments in micropitting studies have been achieved recently by many researchers and engineers on both theoretical and experimental fields, large amounts of investigations are yet to be further launched to thoroughly understand the micropitting mechanism. This work reviews recent relevant studies on the micropitting of steel gears, especially the competitive phenomenon that occurs among several contact fatigue failure modes when considering gear tooth surface wear evolution. Meanwhile, the corresponding recent research results about gear micropitting issues obtained by the authors are also displayed for more detailed explanations.
“…Martensite decay in bearings has been amply investigated and excellent reviews can be found in [5,6]. There are fewer published reports on martensite decay in gears [3,[7][8][9][10][11][12][13][14][15][16][17][18] but they all describe dark and/or white etching features as in bearings. A major difference between martensite decay in bearings and martensite decay in gears is the location where the transformation occurs.…”
Molecular dynamics simulations were used to study the phenomenon of martensite decay in gears by deforming a grinding mark subjected to contact stresses exerted by a rigid plate. The velocities imposed on the rigid plate and the interatomic potential chosen to represent the interactions between the rigid plate and the grinding mark allow for a realistic representation of an elastohydrodynamic contact with an average friction coefficient of 0.05 and all values below 0.1. Due to the initial plastic deformation the height of the grinding mark reduces significantly between two loading cycles, consequently, during the second loading cycle the deformation is predominantly elastic and dislocations only nucleate during the first loading cycle. The diffusion of carbon atoms from the grinding mark leads to the formation of plate-like regions depleted in carbon and precipitation of cementite, the products of martensite decay, as observed experimentally.
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