The proportion between the gear bending fatigue crack initiation and total life: A quantitative study

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis Pub Date : 2025-04-15 DOI:10.1016/j.engfailanal.2025.109611

Haifeng He , Dongdong Yang , Zhaohong Ren , Rongchen Zhao , Jiahong Huang

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Abstract

The bending fatigue performance of gears is a critical determinant of equipment safety and operational reliability, and thus has been extensively studied. Despite this, the experimental quantitative investigation into the crack initiation and propagation within gear bending fatigue remains incomplete. In this study, a comprehensive series of bending fatigue tests based on the resonance fatigue test machine were conducted to elucidate the proportion between the gear bending fatigue crack initiation life and total life. The microstructure and the fracture morphology were investigated using the scanning electron microscope (SEM). The instant when the loading frequency decreases by 2% is defined as the transition point between fatigue crack initiation and propagation. In total 65 set of fatigue test data with different surface treatments, casting states, and gear material were obtained to determine this proportion. Results show that the proportion between crack initial fatigue life and total fatigue life is larger than 95% for the high cycle fatigue regime, regardless of effects induced by loading amplitude, shot peening treatment, casting state and gear material.

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齿轮弯曲疲劳裂纹起始与总寿命之间的比例：定量研究

齿轮的弯曲疲劳性能是决定设备安全性和运行可靠性的关键因素，因此得到了广泛的研究。尽管如此，对齿轮弯曲疲劳裂纹萌生和扩展的实验定量研究仍然不完整。在共振疲劳试验机上进行了一系列全面的弯曲疲劳试验，阐明了齿轮弯曲疲劳裂纹萌生寿命与总寿命的比例关系。利用扫描电子显微镜（SEM）对其显微组织和断口形貌进行了研究。将加载频率减小2%的瞬间定义为疲劳裂纹萌生和扩展的过渡点。共获得了65组不同表面处理、铸造状态和齿轮材料的疲劳试验数据，以确定该比例。结果表明：在不考虑加载幅度、喷丸处理、铸造状态和齿轮材料影响的情况下，高周疲劳状态下裂纹初始疲劳寿命与总疲劳寿命之比大于95%；

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Engineering Failure Analysis 工程技术-材料科学：表征与测试

CiteScore

7.70

自引率

20.00%

发文量

956

审稿时长

47 days

期刊介绍： Engineering Failure Analysis publishes research papers describing the analysis of engineering failures and related studies. Papers relating to the structure, properties and behaviour of engineering materials are encouraged, particularly those which also involve the detailed application of materials parameters to problems in engineering structures, components and design. In addition to the area of materials engineering, the interacting fields of mechanical, manufacturing, aeronautical, civil, chemical, corrosion and design engineering are considered relevant. Activity should be directed at analysing engineering failures and carrying out research to help reduce the incidences of failures and to extend the operating horizons of engineering materials. Emphasis is placed on the mechanical properties of materials and their behaviour when influenced by structure, process and environment. Metallic, polymeric, ceramic and natural materials are all included and the application of these materials to real engineering situations should be emphasised. The use of a case-study based approach is also encouraged. Engineering Failure Analysis provides essential reference material and critical feedback into the design process thereby contributing to the prevention of engineering failures in the future. All submissions will be subject to peer review from leading experts in the field.