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Evaluation of contact fatigue risk of a carburized gear considering gradients of mechanical properties

Friction 2020年第6期8卷 1039-1050页

作者： Wei WANG Huaiju LIU Caichao ZHU Jinyuan TANG Chenxu JIANG State Key Laboratory of Mechanical Transmissions Chongqing UniversityChongqing 400030China State Key Laboratory of High Performance Complex Manufacturing Central South UniversityChangsha 410083China College of Aerospace Engineering Chongqing UniversityChongqing 400044China

carburized gears are widely used in geared machines such as wind *** fatigue problems occur in engineering practice,reducing reliabilities of *** fatigue failures are related to many factors,such as gradients of mechanical properties of the hardening *** this work,an elastic-plastic contact model of a carburized gear is developed based on the finite element method to evaluate contact fatigue failure risk,considering variations in hardness and *** Dang Van multiaxial equivalent stress is calculated via Python coding within the Abaqus *** gradient of yield strength along the depth from case to core is *** concept of local material fatigue failure risk is defined to evaluate the probability of pitting *** effects of design factors,such as the case hardening depth(CHD),surface hardness,and contact pressure on fatigue failure risk,are *** the CHD increases or the surface hardness decreases,the risk of deep spalling failure *** increase in surface hardness leads to a decreased risk of pitting failure,while the variation in CHD hardly affects the pitting failure risk.

关键词： carburized gear multiaxial stress hardness gradient pitting spalling

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Experimental investigation of the relation between the surface integrity and bending fatigue strength of carburized gears

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Science China(Technological Sciences) 2023年第1期66卷 33-46页

作者： CHEN DiFa ZHU JiaZan LIU HuaiJu WEI PeiTang MAO TianYu State Key Laboratory of Mechanical Transmissions Chongqing UniversityChongqing 400044China China Gas Turbine Establishment Chengdu 710025China

Bending fatigue is an essential parameter that needs to be considered in the improvement process of the power density and reliability of gear drives. Quantitative relations among the manufacturing parameters, surface integrities, and fatigue performance are not clear, which seriously limits the effectiveness of an anti-fatigue design. For this work, tooth-bending fatigue tests of carburized gears with different surface integrities were performed using a pulsator. The effects of the manufacturing parameters and surface integrities on the gear fatigue, such as surface hardness and residual stress, were investigated. The experimental results revealed that due to the improvement of surface integrities after shot peening, the nominal bending stress number(fatigue limit) increased by 6.3%–31.1%, with an amplitude range of 39–143 MPa. A supervised learning algorithm of a random forest was implemented to determine the contribution of the surface hardness and surface residual stress to the nominal stress number. An empirical formula was proposed to predict the nominal stress number considering the surface integrities. The prediction error was less than 7.53%, as verified by several gear-bending fatigue tests. This provided theoretical support for the modern, anti-fatigue design of the gears.

关键词： carburized gear surface integrity bending fatigue design formula

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维普期刊数据库

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Study on contact fatigue of a wind turbine gear pair considering surface roughness

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Friction 2020年第3期8卷 553-567页

作者： Heli LIU Huaiju LIU Caichao ZHU Zhangdong SUN Houyi BAI State Key Laboratory of Mechanical Transmissions Chongqing UniversityChongqing 400030China Hubei University of Automotive Technology Shiyan 442002HubeiChina Chongqing Wangjiang Industrial Co.Chongqing 400071China

Contact fatigue issues become more and more crucial in gear industry as they significantly affect the reliability and service life of associated mechanical systems such as wind turbine *** contact fatigue behavior is mostly determined by the mechanical properties of materials and stress fields near the contact area,which is further influenced by the lubrication and surface roughness due to pressure *** this study,a numerical model incorporating the lubrication state,tooth surface roughness,residual stress,and mechanical properties of the material is developed to determine the contact fatigue behavior of a megawatt level wind turbine carburized *** variations of the hardness and residual stress along the depth were characterized by the Vickers hardness measurement and X-ray diffraction test,*** elastohydrodynamic lubrication theory was applied to predict the contact pressure distribution,highlighting the influence of the surface roughness that stemed from the original measurement through an optical *** stress histories of the studied material points during a complete contact loading cycle were fast calculated using the discreteconcrete fast Fourier transformation(DC-FFT)*** Dang Van diagrams under different working conditions were determined to estimate the contact fatigue failure *** effect of the root mean square(RMS)value of the surface roughness on the failure risk at critical material points were discussed in *** revealed that the surface roughness significantly increases the contact fatigue failure risk within a shallow area,and the maximum risk appears near the surface.

关键词： carburized gear contact fatigue surface roughness residual stress Dang Van criterion

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