Computational model for simulation of surface pitting on gears
Glodež, Srečko ; Ren, Zoran
A computational model for simulating surface pitting on spur gears is presented. The model considers the material fatigue process leading to pitting, i.e. the conditions required for crack initiation ...and then the simulation of fatigue crack propagation. The theory of dislocation motion on persistent slip bands is used to describe the process of crack initiation. The simulation of fatigue crack propagation takes into account the short crack growth theory, where the microstructure of a material plays a crucial role. For computational simulations of crack initiation and crack propagation in the contact area of spur gear teeth, an equivalent two-dimensional model of two cyliners is used, where Hertzian contact conditions with the addition of sliding contact forces are assumed. The stress field in the contact area of meshing spur gear teeth and the functional relationship between the stress intensity factor and the propagating crack length are determined by the finite element method. The virtual crack extension method in the framework of the fimite element analysis is applied for simulation of the fatigue short crack under contact loading from the initial crack up to the formation of the surface pit. On the basis of numerical results, and with consideration of some particular material parameters, the service life of gear teeth is estimated in regard to surface pitting. As a practical example the model is used for simulation of surface pitting of two meshing gears, which have been experimentally tested. Numerically predicted pit shapes of gear teeth flanks and the time required for their formation show good agreement with experimental observations. The model is clarly capable of simulating the surface fatigue process and can be reliably used for numerical predictions of the service life of spur gears.
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