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Technical Brief

An Approach for the Gear Rolling Contact Fatigue Acceleration

[+] Author and Article Information
Sheng Li

Department of Mechanical and Materials Engineering,
Wright State University,
3640 Colonel Glenn Highway,
Dayton, OH 45435
e-mail: sheng.li@wright.edu

Jeremy J. Wagner

John Deere Product Engineering Center,
PO Box 8000,
Waterloo, IA 50704

1Corresponding author.

Contributed by the Power Transmission and Gearing Committee of ASME for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received June 8, 2015; final manuscript received December 2, 2015; published online January 6, 2016. Assoc. Editor: Qi Fan.

J. Mech. Des 138(3), 034501 (Jan 06, 2016) (3 pages) Paper No: MD-15-1414; doi: 10.1115/1.4032267 History: Received June 08, 2015; Revised December 02, 2015

This study proposes an approach for the acceleration of the experimental gear rolling contact fatigue (RCF) crack formation. By increasing the rotational velocity of a gear pair, the RCF experimental time period is reduced. However, the film thickness is increased to improve the fatigue performance, to counteract which it is proposed to raise the lubricant temperature to reduce the film thickness. A physics-based gear contact fatigue model is used to quantify and offset the effects of the rotational velocity and the lubricant temperature on the crack nucleation.

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References

Li, S. , and Kahraman, A. , 2011, “ A Fatigue Model for Contacts Under Mixed Elastohydrodynamic Lubrication Condition,” Int. J. Fatigue, 33(3), pp. 427–436. [CrossRef]
Li, S. , and Kahraman, A. , 2013, “ A Physics-Based Model to Predict Micro-Pitting Lives of Lubricated Point Contacts,” Int. J. Fatigue, 47, pp. 205–215. [CrossRef]
Li, S. , and Kahraman, A. , 2013, “ Micro-Pitting Fatigue Lives of Lubricated Point Contacts: Experiments and Model Validation,” Int. J. Fatigue, 48, pp. 9–18. [CrossRef]
Li, S. , Kahraman, A. , and Klein, M. , 2012, “ A Fatigue Model for Spur Gear Contacts Operating Under Mixed Elastohydrodynamic Lubrication Conditions,” ASME J. Mech. Des., 134(4), p. 041007. [CrossRef]
Cheng, W. , and Cheng, H. S. , 1995, “ Effect of Surface Roughness Orientation on Pitting Resistance of Lubricated Rollers,” Tribol. Trans., 38(2), pp. 396–402. [CrossRef]
Li, S. , 2015, “ A Computational Study on the Influence of Surface Roughness Lay Directionality on Micropitting of Lubricated Point Contacts,” ASME J. Tribol., 137(2), p. 021401. [CrossRef]
Winter, H. , and Weiss, T. , 1981, “ Some Factors Influencing the Pitting, Micro-Pitting (Frosted Areas) and Slow Speed Wear of Surface Hardened Gears,” ASME J. Mech. Des., 103(2), pp. 499–505. [CrossRef]
Oila, A. , and Bull, S. J. , 2005, “ Assessment of the Factors Influencing Micropitting in Rolling/Sliding Contacts,” Wear, 258(10), pp. 1510–1524. [CrossRef]
Hoffmann, G. , Hanejko, F. G. , and Slattery, R. H. , 2006, “ Crack Initiation and Propagation in RCF, a New Approach to Understanding Pitting Failure of Highly Loaded Gears,” SAE Paper No. 2006-01-0383.
Lainé, E. , Olver, A. V. , and Beveridge, T. A. , 2008, “ Effect of Lubricants on Micropitting and Wear,” Tribol. Int., 41(11), pp. 1049–1055. [CrossRef]
Li, S. , Kahraman, A. , Anderson, N. E. , and Wedeven, L. D. , 2013, “ A Model to Predict Scuffing Failures of a Ball-On-Disk Contact,” Tribol. Int., 60, pp. 233–245. [CrossRef]
Li, S. , 2013, “ Influence of Surface Roughness Lay Directionality on Scuffing Failure of Lubricated Point Contacts,” ASME J. Tribol., 135(4), p. 041502. [CrossRef]
Li, S. , 2015, “ A Thermal Tribo-Dynamic Mechanical Power Loss Model for Spur Gear Pairs,” Tribol. Int., 88, pp. 170–178. [CrossRef]
Li, S. , and Kahraman, A. , 2011, “ Influence of Dynamic Behavior on Elastohydrodynamic Lubrication of Spur Gears,” J. Eng. Tribol., 225(8), pp. 740–753.
Li, S. , and Kahraman, A. , 2011, “ A Spur Gear Mesh Interface Damping Model Based on Elastohydrodynamic Contact Behavior,” Int. J. Powertrains, 1(1), pp. 4–21. [CrossRef]
Li, S. , and Kahraman, A. , 2013, “ A Tribo-Dynamic Model of a Spur Gear Pair,” J. Sound Vib., 332(20), pp. 4963–4978. [CrossRef]
Li, S. , 2014, “ A Boundary Element Model for Near Surface Contact Stresses of Rough Surfaces,” Comput. Mech., 54(3), pp. 833–846. [CrossRef]
Li, S. , 2015, “ An Investigation on the Influence of Misalignment of Micro-Pitting of a Spur Gear Pair,” Tribol. Lett., 60(3), p. 35. [CrossRef]

Figures

Grahic Jump Location
Fig. 1

The distribution of crack formation fatigue life along the critical transverse plane of gear 1 tooth under the baseline condition

Grahic Jump Location
Fig. 2

The plane strain multi-axial stress fields at the critical mesh position under the baseline condition

Grahic Jump Location
Fig. 3

The distribution of the fatigue life deviation from the baseline

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