A numerical model for total bending fatigue life estimation of carburized spur gears considering the hardness gradient and residual stress

IF 1.9 3区工程技术 Q3 MECHANICS Meccanica Pub Date : 2024-06-21 DOI:10.1007/s11012-024-01841-y

Xianshun Sun, Jun Zhao, Shaokang Song, Yongliang Lu, Huiyang Sun

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Abstract

The paper introduces a novel three-dimensional numerical model considering hardness gradient and residual stress to predict carburized gears’ total bending fatigue life. The crack initiation life was forecasted by the strain life method, considering hardness gradient and residual stress. Linear elastic stresses and strains in the tooth root fillet were corrected by Neuber’s rule for elastic–plastic material behavior. The tooth root area of the spur gear is segmented into layers using the thin slice method, and the fatigue properties of each layer are determined using the multilayer method. The crack propagation life was predicted by the extended finite element method (XFEM), considering hardness gradient and residual stress. Fracture surface analysis with electron microscopy determines the exact location where cracks initiate. The high-speed camera records the path and life of crack propagation. Single-tooth bending fatigue life (STBF) tests are conducted to validate the proposed model. The predicted fatigue lifetimes, failure locations, and crack propagation paths agree well with the experimental results.

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考虑硬度梯度和残余应力的渗碳直齿轮总弯曲疲劳寿命估算数值模型

本文介绍了一种考虑硬度梯度和残余应力的新型三维数值模型，用于预测渗碳齿轮的总弯曲疲劳寿命。在考虑硬度梯度和残余应力的情况下，采用应变寿命法预测了裂纹起始寿命。齿根圆角处的线性弹性应力和应变根据弹塑性材料行为的 Neuber 规则进行修正。使用薄片法将正齿轮的齿根区域划分为若干层，并使用多层法确定每一层的疲劳特性。考虑到硬度梯度和残余应力，采用扩展有限元法（XFEM）预测了裂纹扩展寿命。利用电子显微镜进行的断裂表面分析确定了裂纹产生的确切位置。高速摄像机记录了裂纹扩展的路径和寿命。进行了单齿弯曲疲劳寿命（STBF）测试，以验证所提出的模型。预测的疲劳寿命、失效位置和裂纹扩展路径与实验结果非常吻合。

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来源期刊

Meccanica 物理-力学

CiteScore

4.70

自引率

3.70%

发文量

151

审稿时长

7 months

期刊介绍： Meccanica focuses on the methodological framework shared by mechanical scientists when addressing theoretical or applied problems. Original papers address various aspects of mechanical and mathematical modeling, of solution, as well as of analysis of system behavior. The journal explores fundamental and applications issues in established areas of mechanics research as well as in emerging fields; contemporary research on general mechanics, solid and structural mechanics, fluid mechanics, and mechanics of machines; interdisciplinary fields between mechanics and other mathematical and engineering sciences; interaction of mechanics with dynamical systems, advanced materials, control and computation; electromechanics; biomechanics. Articles include full length papers; topical overviews; brief notes; discussions and comments on published papers; book reviews; and an international calendar of conferences. Meccanica, the official journal of the Italian Association of Theoretical and Applied Mechanics, was established in 1966.