With the mounting application of carburized or case-hardening gears and higher requirements of heavy-load, high-speed in mechanical systems such as wind turbines, helicopters, ships, etc., contact fatigue issues of gears are becoming more preponderant. Recently, significant improvements have been made on the gear manufacturing process to control subsurface-initiated failures, hence, gear surface-initiated damages, such as micropitting, should be given more attention. The diversity of the influence factors, including gear materials, surface topographies, lubrication properties, working conditions, etc., are necessary to be taken into account when analyzing gear micropitting behaviors. Although remarkable developments in micropitting studies have been achieved recently by many researchers and engineers on both theoretical and experimental fields, large amounts of investigations are yet to be further launched to thoroughly understand the micropitting mechanism. This work reviews recent relevant studies on the micropitting of steel gears, especially the competitive phenomenon that occurs among several contact fatigue failure modes when considering gear tooth surface wear evolution. Meanwhile, the corresponding recent research results about gear micropitting issues obtained by the authors are also displayed for more detailed explanations.
1 November 2022 in Ultrasound in Obstetrics & Gynecology
Gear contact fatigue has becoming a bottleneck restricting the safety and reliability of wind turbine transmission systems. Tooth interior fatigue fracture (TIFF) failure is commonly observed in case-hardened wind turbine gears. In this work, a contact fatigue model is developed to investigate the effect of design parameters and material properties on TIFF of wind turbine gears. The sub-surface stress field is obtained by superposing the load-introduced stress and initial residual stress. The hardness gradient of the hardened layer is measured by Vickers hardness tests. Based upon the stress field and material properties, a fatigue parameter analysis is presented to characterize the risk of TIFF by using the Dang Van multiaxial fatigue criterion. Results show that the risk of TIFF increases with increasing external load. Increasing pressure angle and residual compressive stress could reduce TIFF risk. The combination of high surface hardness, low core hardness, and large effective case depth could inhibit the crack initiation.
Micropitting is a typical surface contact fatigue in rolling–sliding contact. The kinematic sliding is of great significance in the initiation and progression of micropitting. A numerical surface fatigue model considering rolling–sliding contact and surface evolution is developed based on mixed-EHL (elastohydrodynamic lubrication) theory, rainflow cycle counting method and Archard’s law. Surface evolution is evaluated using Archard’s wear law based on measured teeth surface topography. Surface damage is determined via the Palmgren–Miner line rule and Goodman diagrams. The effect of rolling speed and surface roughness are discussed in detail. Results show that stress micro-cycles are introduced by rough sliding in the rolling–sliding contact. The mild wear reduces the height of asperities, the maximum pressure and alleviates subsurface stress concentration. For rolling–sliding contact, the faster moving surface dominates the composite height of asperities, then decides the fluctuations of pressure, as well as stress ranges. The combination of surface topography should be considered in the surface design.
18 May 2021 in Fatigue & Fracture of Engineering Materials & Structures