Tooth flank fracture – An applied fatigue study of case hardened bevel gears

Böhme, Stephan André; Szanti, Gabor; Keski-Rahkonen, Joni; Komssi, Tami; Santaella, José Garcia; Vinogradov, Alexei

doi:10.1016/j.engfailanal.2021.105911

Cited by 12 publications

(16 citation statements)

References 7 publications

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“…The DV criterion yields its 1.06 utilization peak in the TFF-typical depth of 4.4 mm, indicating a substantial risk for TFF even under the considered moderate loads. The high utilization corresponds well with the large number of observed crack-like indications from ultrasonic scanning on G1 [3]. To demonstrate the criterion's applicability to the study of all LTCA contact points between meshing pinion and wheel teeth, the material utilization of a G1 pinion tooth is plotted in Fig.…”

Section: K 3 Discussionsupporting

confidence: 52%

“…Gear set G1 will be used to visualize and verify the proposed analytical equations against an accurate, 2D plane strain, numerical stress prediction in the gear's mean cross-section [3]. Figure 2 plots the LTCA-derived contact stresses H;i and radii of curvature eq;i across a G1 pinion tooth and its mean cross-section.…”

Section: Methodsmentioning

confidence: 99%

“…Failure investigations of the affected gear teeth reveal predominantly surface-parallel cracks of elliptical shape underneath the loadcarrying flank. Over a 3-year period, 174 and 32 cracklike indications were detected on 16 G1 and 6 G2 gear sets respectively [3]. Two examples of G1 gear teeth are given in Fig.…”

Section: Stress Modelmentioning

confidence: 99%

“…From the hardness profile, the necessary uniaxial fatigue strength under alternating load f −1 and fatigue ratio Ä are estimated. Whereas f −1 was calibrated to match the material utilizations of the herein proposed TFF criterion against the BO criterion detailed in [3][4][5], Ä relies on the fatigue tests performed on 18CrNiMo7-6, 34CrNiMo6 and 18NiCrMo14-6 steels at multiple forging ratios and material cleanlinesses [1]. The steels were tested under uniaxial stresses at R = -1 and R = 0 in the high and very high cycle fatigue regime and under shear at R = -1 in the high cycle fatigue regime.…”

Section: Strength Modelmentioning

confidence: 99%

“…It continues the efforts of the 'Improved reliability of thrusters' joint industry project-a cooperation between thruster suppliers, gear manufacturers, steel suppliers, forging companies and the maritime classification society Det Norske Veritas (DNV). The article combines the previously published findings on the material properties of carburized CrNiMo steels [1], the stress and fatigue predictions in the mean cross-section of spiral bevel gear teeth [3], the test results from back-to-back gear testing [4] and the observations from early-stage tooth flank fracture on large maritime bevel gears [2,5] to a standardizable approach for the prediction and ultimately prevention of tooth flank fracture (TFF).…”

Section: Introductionmentioning

confidence: 99%

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A standardizable approach for Tooth Flank Fracture

Böhme

Keski-Rahkonen²,

Komssi³

2022

Forsch Ingenieurwes

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Ultrasonic scanning of large spiral bevel gears and the subsequent fracture analyses of early-stage tooth flank fractures imply a mode II crack initiation under surface-parallel, orthogonal shear stresses. An iteration of the Dang Van criterion is presented that focuses exclusively on surface-parallel material planes, yielding a standardizable approach for the study of tooth flank fracture in spiral bevel gears. It is shown that Dang Van’s shear stress amplitude and maximum hydrostatic stress along a surface-perpendicular path can adequately be described by the Hertzian orthogonal shear stress amplitude and Lang’s compressive residual stress. The fatigue properties along the same path are estimated from Thomas’ hardness model and augmented by ISO-inspired lifetime, size and conversion factors. The article closes with a comparison between the commonly used Witzig-Boiadjiev, Hertter-Wirth, DNV subsurface fatigue and the herein proposed, rationalized Dang Van criterion.

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Section: K 3 Discussionsupporting

confidence: 52%

Section: Methodsmentioning

confidence: 99%

Section: Stress Modelmentioning

confidence: 99%

Section: Strength Modelmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

A standardizable approach for Tooth Flank Fracture

Böhme

Keski-Rahkonen²,

Komssi³

2022

Forsch Ingenieurwes

Self Cite

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Flank fractures on spiral bevel gears—transfer of analytical methods for the estimation of residual stresses from cylindrical gears to bevel gears

Truong,

Ulrich,

Schumann

et al. 2024

Forsch Ingenieurwes

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The classic flank and root load capacity calculation on the component surface forms the basis for the design of power gears today. However, flank fractures also occur in practice, particularly with large-module gears and/or low case-hardening depths. It is a fatigue damage with crack initiation in the tooth interior, its prevention requires the calculation of the stresses below the surface. In addition to understanding the load stresses, the inhomogeneous load bearing capacity and the residual stress profile in case-hardened gears are also of great importance. There are various calculation approaches for this in the area of cylindrical gears, but these have not yet been transferred to the complex geometry of spiral bevel gears. The focus of this publication is on estimating the residual stresses in the tooth volume by generating a three-dimensional residual stress tensor field in the bevel gear tooth based on the two-dimensional calculation approaches used to date on cylindrical gears. In combination with the stress tensor-time curves from a tooth contact simulation with the LTCA tool BECAL, this can be fed into different failure hypotheses, which is illustrated using an example.

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The Design of Hardened Case and Carburizing Process of Subway Gear Based on Spalling Fatigue

Wang,

2024

J Fail. Anal. and Preven.

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Tooth flank fracture – An applied fatigue study of case hardened bevel gears

Cited by 12 publications

References 7 publications

A standardizable approach for Tooth Flank Fracture

A standardizable approach for Tooth Flank Fracture

Flank fractures on spiral bevel gears—transfer of analytical methods for the estimation of residual stresses from cylindrical gears to bevel gears

The Design of Hardened Case and Carburizing Process of Subway Gear Based on Spalling Fatigue

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