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Contact fatigue damage of gears
Fajdiga, Gorazd ; Šraml, Matjaž ; Flašker, Jože
Two kinds of teeth damage can occur on gears under cyclic contact loading due to material fatigue - the pitting of gear teeth flanks and tooth breakage in the tooth root. In this study only the ...pitting phenomenon is addressed and the developed two-dimensional computational model for simulation of contact fatigue of gear teeth flanks is used for determination of pitting resistance, i.e. the service life of gear teeth flanks. The fatigue process leading to pitting is divided into crack initiation and crack propagation period that leads to the appearance of small pits on the contact surface. The model for prediction of identification of critical material areas and the number of loading cycles, required for initial fatigue crack to appear, is based on Coffin-Manson relations between deformations and loading cycles, and comprise characteristic material fatigue parameters. The computational approach is based on continuum mechanics, where homogenous and elastic material model is assumed and results of cyclic loading conditions are obtained using the finite element method analysis. The short crack theory together with the finite element method is then used for simulation of the fatigue crack growth. The governing factors are the initial crack length, crack angle, contact pressure which takes into account the EHD-lubrication conditions, tangential loading due to friction between contacting surfaces, moving contact conditions, residual stresses due to heat treatment of the material and the hydraulic pressure of trapped fluid acting on the crack surface. The virtual crack extension (VCE) method, implemented in the finite element method, is than used for simulating the fatigue crack propagation from the initial crack up to the formation of the surface pit. The relationship between the stress intensity factor K and crack length a, which is needed for determination of the required number of loading cycles Np for a crack propagation from the initial to the critical length, is shown and with consideration of some particular material parameters, the service life of gear teeth flanks is estimated.
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