Contact fatigue life prediction of a bevel gear under spectrum loading

Pan JIA, Huaiju LIU, Caichao ZHU, Wei WU, Guocheng LU

PDF(1402 KB)
PDF(1402 KB)
Front. Mech. Eng. ›› 2020, Vol. 15 ›› Issue (1) : 123-132. DOI: 10.1007/s11465-019-0556-8
RESEARCH ARTICLE

Contact fatigue life prediction of a bevel gear under spectrum loading

Author information +
History +

Abstract

Rolling contact fatigue (RCF) issues, such as pitting, might occur on bevel gears because load fluctuation induces considerable subsurface stress amplitudes. Such issues can dramatically affect the service life of associated machines. An accurate geometry model of a hypoid gear utilized in the main reducer of a heavy-duty vehicle is developed in this study with the commercial gear design software MASTA. Multiaxial stress–strain states are simulated with the finite element method, and the RCF life is predicted using the Brown–Miller–Morrow fatigue criterion. The patterns of fatigue life on the tooth surface are simulated under various loading levels, and the RCF S–N curve is numerically generated. Moreover, a typical torque–time history on the driven axle is described, followed by the construction of program load spectrum with the rain flow method and the Goodman mean stress equation. The effects of various fatigue damage accumulation rules on fatigue life are compared and discussed in detail. Predicted results reveal that the Miner linear rule provides the most optimistic result among the three selected rules, and the Manson bilinear rule produces the most conservative result.

Keywords

bevel gear / rolling contact fatigue (RCF) / multiaxial fatigue criterion / load spectrum / damage accumulation rule

Cite this article

Download citation ▾
Pan JIA, Huaiju LIU, Caichao ZHU, Wei WU, Guocheng LU. Contact fatigue life prediction of a bevel gear under spectrum loading. Front. Mech. Eng., 2020, 15(1): 123‒132 https://doi.org/10.1007/s11465-019-0556-8

References

[1]
Niemann G, Rettig H, Lechner G. Scuffing tests on gear oils in the FZG apparatus. A S L E Transactions, 1961, 4(1): 71–86
CrossRef Google scholar
[2]
Höhn B R, Michaelis K, Doleschel A. Frictional behaviour of synthetic gear lubricants. Tribology Series, 2001, 39: 759–768
CrossRef Google scholar
[3]
He H, Liu H, Zhu C, Study of rolling contact fatigue behavior of a wind turbine gear based on damage-coupled elastic-plastic model. International Journal of Mechanical Sciences, 2018, 141: 512–519
CrossRef Google scholar
[4]
Fernandes P J L, McDuling C. Surface contact fatigue failures in gears. Engineering Failure Analysis, 1997, 4(2): 99–107
CrossRef Google scholar
[5]
Liu H, Liu H, Zhu C, Evaluation of contact fatigue life of a wind turbine gear pair considering residual stress. Journal of Tribology, 2018, 140(4): 041102
CrossRef Google scholar
[6]
Carpinteri A, Spagnoli A, Vantadori S. A review of multiaxial fatigue criteria for random variable amplitude loads. Fatigue & Fracture of Engineering Materials & Structures, 2017, 40(7): 1007–1036
CrossRef Google scholar
[7]
Wang W, Liu H, Zhu C, Effect of the residual stress on contact fatigue of a wind turbine carburized gear with multiaxial fatigue criteria. International Journal of Mechanical Sciences, 2019, 151: 263–273
CrossRef Google scholar
[8]
Wang W, Liu H, Zhu C, Micromechanical analysis of gear fatigue-ratcheting damage considering the phase state and inclusion. Tribology International, 2019, 136: 182–195
CrossRef Google scholar
[9]
Wu Z R, Hu X T, Song Y D. Multiaxial fatigue life prediction for titanium alloy TC4 under proportional and nonproportional loading. International Journal of Fatigue, 2014, 59: 170–175
CrossRef Google scholar
[10]
Zhu S P, Yu Z Y, Correia J, Evaluation and comparison of critical plane criteria for multiaxial fatigue analysis of ductile and brittle materials. International Journal of Fatigue, 2018, 112: 279–288
CrossRef Google scholar
[11]
Litvin F L, Fuentes A, Hayasaka K. Design, manufacture, stress analysis, and experimental tests of low-noise high endurance spiral bevel gears. Mechanism and Machine Theory, 2006, 41(1): 83–118
CrossRef Google scholar
[12]
Sekercioglu T, Kovan V. Pitting failure of truck spiral bevel gear. Engineering Failure Analysis, 2007, 14(4): 614–619
CrossRef Google scholar
[13]
Bhavi I, Kuppast V, Kurbet S. Experimental setup and methodology to carryout fatigue testing of spiral bevel gears used in differential gear box using NVH approach. Applied Mechanics and Materials, 2016, 852: 545–550
CrossRef Google scholar
[14]
Ural A, Heber G, Wawrzynek P A, Three-dimensional, parallel, finite element simulation of fatigue crack growth in a spiral bevel pinion gear. Engineering Fracture Mechanics, 2005, 72(8): 1148–1170
CrossRef Google scholar
[15]
Deng S, Hua L, Han X, Finite element analysis of contact fatigue and bending fatigue of a theoretical assembling straight bevel gear pair. Journal of Central South University, 2013, 20(2): 279–292
CrossRef Google scholar
[16]
Liu F, Wu W, Hu J, Design of multi-range hydro-mechanical transmission using modular method. Mechanical Systems and Signal Processing, 2019, 126: 1–20
CrossRef Google scholar
[17]
Liu S, Song C, Zhu C, Investigation on the influence of work holding equipment errors on contact characteristics of face-hobbed hypoid gear. Mechanism and Machine Theory, 2019, 138: 95–111
CrossRef Google scholar
[18]
Medepalli S, Rao R. Prediction of road loads for fatigue design—A sensitivity study. International Journal of Vehicle Design, 2000, 23(1–2): 161–175
CrossRef Google scholar
[19]
Liu X, Li D, Lv W, Research on analysis approach of strength and fatigue life of horizontal axis wind turbine hub. Acta Energiae Solaris Sinica, 2012, 5: 18–23 (in Chinese)
[20]
Shinde V, Jha J, Tewari A, Modified rainflow counting algorithm for fatigue life calculation. In: Seetharamu S, Rao K, Khare R, eds. Proceedings of Fatigue, Durability and Fracture Mechanics. Singapore: Springer, 2018, 381–387
CrossRef Google scholar
[21]
Mayer H, Ede C, Allison J E. Influence of cyclic loads below endurance limit or threshold stress intensity on fatigue damage in cast aluminium alloy 319-T7. International Journal of Fatigue, 2005, 27(2): 129–141
CrossRef Google scholar
[22]
Hu H, Yan Y M. Light bus drive axle design. Applied Mechanics and Materials, 2013, 380–384: 17–22
CrossRef Google scholar
[23]
Carpinteri A, Spagnoli A. Multiaxial high-cycle fatigue criterion for hard metals. International Journal of Fatigue, 2001, 23(2): 135–145
CrossRef Google scholar
[24]
Patra A P, Bidhar S, Kumar U. Failure prediction of rail considering rolling contact fatigue. International Journal of Reliability Quality and Safety Engineering, 2010, 17(03): 167–177
CrossRef Google scholar
[25]
Brown M W, Miller K J. A theory for fatigue failure under multiaxial stress-strain conditions. Proceedings of Institution of Mechanical Engineers, 1973, 187(1): 745–755
CrossRef Google scholar
[26]
Kumbhar S V, Kulkarni V, Tayade R M. Low cycle fatigue analysis of after treatment device induced due to thermal load by using finite element analysis. Applied Mechanics and Materials, 2014, 592–594: 1104–1108
CrossRef Google scholar
[27]
Wen B Z, Li J M, Pei Z T, Statistical analysis of loader’s drive axle housing random load spectrum. Advanced Materials Research, 2011, 338: 456–459
CrossRef Google scholar
[28]
Grubisic V, Fischer G, Heinritz M. Design Optimization of Forged Wheel Hubs for Commercial Vehicles. SAE Technical Paper 841706, 1984
CrossRef Google scholar
[29]
Batsoulas Nikolaos D. Cumulative Fatigue Damage: CDM-Based Engineering Rule and Life Prediction Aspect. Steel Research International, 2016, 87(12): 1670–1677
CrossRef Google scholar
[30]
Rege K, Pavlou D G. A one-parameter nonlinear fatigue damage accumulation model. International Journal of Fatigue, 2017, 98: 234–246
CrossRef Google scholar
[31]
Zhao L H, Cai H C, Wang T, Durability assessment of automotive structures under random variable amplitude loading. Advances in Mechanical Engineering, 2018, 10(4): 1687814 018771766
CrossRef Google scholar
[32]
Han Q, Guo Q, Yin Y, Effects of strain ratio on fatigue behavior of G20Mn5QT cast steel. Transactions of Tianjin University, 2016, 22(4): 302–307
CrossRef Google scholar

Acknowledgements

The work was supported by the National Natural Science Foundation of China (Grant No. U1864210), the Open Foundation of the State Key Laboratory of Mechanical Transmissions (Grant No. SKLMT-KFKT-201701), and Chongqing Research Program of Basic Research and Frontier Technology (Grant No. cstc2017jcyjAX0103).

Open Access

This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made.ƒThe images or other third-party materials in this article are included in the article’s Creative Commons license, unless indicated otherwise in a credit line to the material. If a material is not included in the article’s Creative Commons license and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder.ƒTo view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/.

RIGHTS & PERMISSIONS

2019 The Author(s) 2019. This article is published with open access at link.springer.com and journal.hep.com.cn
AI Summary AI Mindmap
PDF(1402 KB)

Accesses

Citations

Detail

Sections
Recommended

/