A numerical model for total contact fatigue life prediction of carburized spur gears considering the surface integrity

IF 1.9 3区工程技术 Q3 MECHANICS

Meccanica Pub Date : 2025-01-28 DOI:10.1007/s11012-025-01935-1

Xianshun Sun, Jun Zhao, Shaokang Song, Yongliang Lu, Huiyang Sun, Xujie Tang

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引用次数: 0

Abstract

Surface integrity has a significant influence on the tooth contact fatigue performance of carburized gears. This paper proposed a total contact fatigue life prediction model considering the hardness gradients, residual stress, and surface roughness. The contact pressure distributions are determined using the elastohydrodynamic lubrication numerical model. The crack initiation life and location are forecasted by the modified Brown-Miller fatigue criterion, considering the surface integrity, loading conditions, and lubrication state. The tooth surface of the spur gear is divided into layers through the thin slicing technique, and the fatigue performance parameters for each layer are determined using the multilayer approach. The crack propagation path and lifespan are predicted by the extended finite element method based on linear elastic fracture mechanics. Contact fatigue life testing is employed to verify the effectiveness of the proposed method for predicting total fatigue life. The damaged areas measured by image analysis are used to monitor crack initiation and determine fatigue failure. Fracture surface analysis conducted with SEM identifies the path of crack propagation. The predicted total contact fatigue life, crack initiation location, and crack extension path agree well with the experimental findings.

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来源期刊

Meccanica 物理-力学

CiteScore

4.70

自引率

3.70%

发文量

151

审稿时长

7 months

期刊介绍： Meccanica focuses on the methodological framework shared by mechanical scientists when addressing theoretical or applied problems. Original papers address various aspects of mechanical and mathematical modeling, of solution, as well as of analysis of system behavior. The journal explores fundamental and applications issues in established areas of mechanics research as well as in emerging fields; contemporary research on general mechanics, solid and structural mechanics, fluid mechanics, and mechanics of machines; interdisciplinary fields between mechanics and other mathematical and engineering sciences; interaction of mechanics with dynamical systems, advanced materials, control and computation; electromechanics; biomechanics. Articles include full length papers; topical overviews; brief notes; discussions and comments on published papers; book reviews; and an international calendar of conferences. Meccanica, the official journal of the Italian Association of Theoretical and Applied Mechanics, was established in 1966.