Shakedown analysis of a wind turbine gear considering strain-hardening and the initial residual stress

Liu, Heli; Liu, Huaiju; Zhu, Caichao; Yuan, Longhua

doi:10.1007/s12206-018-1022-y

Cited by 6 publications

(3 citation statements)

References 19 publications

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“…The basic parameters of this gear pair are listed in Table 1. The pitch point represents the most dangerous meshing position suffered from contact fatigue failure due to the specific kinematics of the gear (He et al., 2018b; Liu et al., 2018b).…”

Section: Simulation Methodologymentioning

confidence: 99%

Analysis of the fatigue crack initiation of a wind turbine gear considering load sequence effect

Liu

Zhu

Wei

et al. 2019

International Journal of Damage Mechanics

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Under the action of the wind, wind turbine gears experience complex loading histories in which the amplitude of the load is varying. The variable load conditions make the load sequence and the load amplitude inverse number as important factors to be considered for gear fatigue analysis. In the present work, a damage-coupled elastic-plastic constitutive model based on the continuous damage mechanics (CDM) is established to analyze the influence of load sequence on rolling contact fatigue (RCF) crack initiation of a wind turbine gear. The crack initiation is indicated by reaching the critical threshold of the defined damage variable related to the shear stress range and the plastic strain. During repeated loading cycles, the deterioration of material is reflected by gradually reducing mechanical properties. The numerical simulation is carried out in the frame of ABAQUS using the subroutine of user defined material subroutine (UMAT). The two-level load conditions are selected and results of which are compared with those of constant amplitude load conditions. Different inverse numbers are utilized to investigate the influence of load amplitude inverse number on crack initiation life. Simulation results are compared with existing damage accumulation criteria. The results indicate that when the first crack initiates, the sum of lifetime ratio is greater than unity for the low-high load sequence, while this value is less than unity for the high-low load sequence. Furthermore, the increase of the load amplitude inverse number will weaken the influence of the load sequence with regard to the crack initiation life. The highly nonlinear characteristic of damage accumulation during fatigue process under variable loading histories is captured by the proposed method. This method provides a new way to reveal the contact fatigue process of gears under variable loading histories and lay a foundation for predicting the accurate fatigue life under the real, complex loading condition of a gear.

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Section: Simulation Methodologymentioning

confidence: 99%

Analysis of the fatigue crack initiation of a wind turbine gear considering load sequence effect

Liu

Zhu

Wei

et al. 2019

International Journal of Damage Mechanics

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“…To address this issue, some scholars have proposed the continuous damage mechanics (CDM), among which the Lemaitre and Chaboche damage-coupled elastic-plastic constitutive formula [22] is widely used. Using the CDM concept, He et al [23][24][25] analyzed the effect of residual stress and loading sequence on fatigue damage evolution during gear rolling contact. They pointed out that the influence of the loading sequence on the contact fatigue life gradually decreased as the frequency of load alternations increased.…”

Section: Introductionmentioning

confidence: 99%

Simulation of the fatigue-wear coupling mechanism of an aviation gear

et al. 2020

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The contact fatigue of aviation gears has become more prominent with greater demands for heavy-duty and high-power density gears. Meanwhile, the coexistence of tooth contact fatigue damage and tooth profile wear leads to a complicated competitive mechanism between surface-initiated failure and subsurface-initiated contact fatigue failures. To address this issue, a fatigue-wear coupling model of an aviation gear pair was developed based on the elastic-plastic finite element method. The tooth profile surface roughness was considered, and its evolution during repeated meshing was simulated using the Archard wear formula. The fatigue damage accumulation of material points on and underneath the contact surface was captured using the Brown-Miller-Morrow multiaxial fatigue criterion. The elastic-plastic constitutive behavior of damaged material points was updated by incorporating the damage variable. Variations in the wear depth and fatigue damage around the pitch point are described, and the effect of surface roughness on the fatigue life is addressed. The results reveal that whether fatigue failure occurs initially on the surface or sub-surface depends on the level of surface roughness. Mild wear on the asperity level alleviates the local stress concentration and leads to a longer surface fatigue life compared with the result without wear.

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“…They suggested that sub-surface contact fatigue should focus on both the risk of pitting and TIFF in the case-core transition area of case-hardened gears. He et al [15] investigated the contact fatigue behavior on heavy-duty conditions by using a developed damage-coupled elastic-plastic contact frame with continuous damage mechanics. They pointed out Over the past decades, special attention has been given to TIFF by FZG [5], SMT [6], KISSsoft [7], and other gear research institutions.…”

Section: Introductionmentioning

confidence: 99%

Study on Tooth Interior Fatigue Fracture Failure of Wind Turbine Gears

Bai

Zhu

Zhou

et al. 2020

Metals

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Gear contact fatigue has becoming a bottleneck restricting the safety and reliability of wind turbine transmission systems. Tooth interior fatigue fracture (TIFF) failure is commonly observed in case-hardened wind turbine gears. In this work, a contact fatigue model is developed to investigate the effect of design parameters and material properties on TIFF of wind turbine gears. The sub-surface stress field is obtained by superposing the load-introduced stress and initial residual stress. The hardness gradient of the hardened layer is measured by Vickers hardness tests. Based upon the stress field and material properties, a fatigue parameter analysis is presented to characterize the risk of TIFF by using the Dang Van multiaxial fatigue criterion. Results show that the risk of TIFF increases with increasing external load. Increasing pressure angle and residual compressive stress could reduce TIFF risk. The combination of high surface hardness, low core hardness, and large effective case depth could inhibit the crack initiation.

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Shakedown analysis of a wind turbine gear considering strain-hardening and the initial residual stress

Cited by 6 publications

References 19 publications

Analysis of the fatigue crack initiation of a wind turbine gear considering load sequence effect

Analysis of the fatigue crack initiation of a wind turbine gear considering load sequence effect

Simulation of the fatigue-wear coupling mechanism of an aviation gear

Study on Tooth Interior Fatigue Fracture Failure of Wind Turbine Gears

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