Research on the gear bending fatigue full-life prediction model of considering hobbing residual stress

Abstract

This study introduces a co-simulation model incorporating the effects of hobbing axial and radial residual stresses (RS). Utilizing Smith-Watson-Topper critical plane fatigue criteria, this study establishes an SWT fatigue life prediction model accounts for axial and radial RS corrections, enabling prediction of crack initiation life (CIL) and crack initiation orientation (CIO). Utilizing maximum circumferential stress criterion and Paris law, this study establishes a tooth root 3D crack propagation model of considering RS, enabling prediction of crack propagation life (CPL) and crack propagation path (CPP). Single tooth bending fatigue (STBF) experiments were performed to assess the predictive accuracy of the model. The findings suggest that radial RS has a greater effect on the full-life compared to axial RS. CPL constitutes roughly 20 % of the full-life. The conclusion demonstrates that the CIL prediction model achieves high accuracy when the axial RS influence coefficient is 0.019 and the radial RS influence coefficient is 0.974. The 3D crack propagation model predicts the CPL and CPP that are well aligned with the actual CPL and CPP. Additionally, the predicted gear bending fatigue full-life (CIL and CPL) lies within the 1.5 scatter factor bond, indicating reliable predictive accuracy of the model across different RS scenarios.