Strength calculations of an element compensating circumferential backlash in the external gear pump

The paper investigated the AW7075 aluminum alloy that is used in the automotive industry. The alloy is widely used, among others, in the production of heads and engine blocks. The possibility of obtaining various properties of the alloy (material states) by appropriate heat treatment (saturation and aging) was demonstrated. The results of strength, hardness, abrasion and fracture toughness tests of the alloy in the T73, RRA and HTPP aging treatments, in comparison with the T651 reference state, are presented. The need to select the appropriate parameters of heat treatment in relation to the load conditions of the structural element, especially in elements with notches, was indicated. Depending on the state of the AW7075 alloy, the results prove the wide and diverse possibilities of its use, and should be used consciously in the design and production processes of modern automotive drivetrain components.

This paper presents the results of durability tests of AW7075 aluminium alloy, which is widely used in producing high-durable and particularly reliable constructions in aeronautical and automotive industries. The plain-strain fracture toughness, depending on the orientation of fracture direction with respect to the rolling direction of the material, and the fatigue crack growth rate were determined. Based on scanning electron microscope (SEM) studies the two stages of fatigue fracture are shown: the first is plastic striations and the second is phenomenon of connecting micropores that were formed around intermetallic second phase particles. As a results of research a model of fatigue crack for the second stage is presented.

This article presents theoretical and experimental calculations of the minimum thickness of a compensation lip used in external gear pumps. Pumps of this type are innovative technical solutions in which circumferential backlash (clearance) compensation is used to improve their volumetric and overall efficiency. However, constructing a prototype of such a pump requires long-lasting research, and the compensation lip is its key object, due to the fact that it is an element influenced by a notch and that it operates in unfavorable conditions of strong fatigue stresses. The theoretical calculations presented in this article are based on identifying maximum stress values in a fatigue cycle and on implementing the stress failure condition and the conditions related to the required value of the fatigue safety factor. The experimental research focuses on static bending tests of the lips as well as on the fatigue loading of the lips in series of tests at increasing stress values until lip failure due to fatigue. The tests allowed the minimum lip thickness to be found for the assumed number of fatigue cycles, which is 2.5 times the number of cycles used in wear margin tests.

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