Skip to main content
SpringerLink
Log in

The Prediction and Experimental Study of Bending Fatigue Life of Carburized Gears

  • Technical Article
  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

Abstract

Tooth bending failure, one of the gear’s most dangerous failure modes, is caused by alternating bending stress at the tooth root. The fatigue process is divided into crack initiation and crack propagation periods. In this paper, single tooth bending fatigue tests are conducted under a stress ratio of 0.05. Crack initiation life is predicted by the strain-life method. Material gradients and residual stresses are taken into account in the above process. The crack propagation life is predicted by linear elastic fracture mechanics. The Paris equation is used to simulate the fatigue crack growth. Finally, the total bending fatigue life can be estimated. Predicted fatigue life and failure locations show good agreement with the experimental results.

Graphical Abstract

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

Data Availability

The datasets used during the current study are available from the corresponding author on reasonable request.

References

  1. X. Cui, N. Sun, J. Guo, J. Ma, and P. Ming, Green Multi-biomimetic Spontaneous Oil-Transport Microstructure and Its Effects on Energy Consumption in Sustainable Intermittent Cutting, J. Clean. Prod., 2022, 367, p 133035. https://doi.org/10.1016/j.jclepro.2022.133035

    Article  CAS  Google Scholar 

  2. X. Cui, S. Duan, J. Guo, and P. Ming, Bionic Multifunctional Surface Microstructure for Efficient Improvement of Tool Performance in Green Interrupted Hard Cutting, J. Mater. Process. Technol., 2022, 305, p 117587. https://doi.org/10.1016/j.jmatprotec.2022.117587

    Article  CAS  Google Scholar 

  3. X. Cui, Y. Guo, J. Guo, and P. Ming, Bio-inspired Design of Cleaner Interrupted Turning and Its Effects on Specific Cutting Energy and Harmful Gas Emission, J. Clean. Prod., 2020, 271, p 122354. https://doi.org/10.1016/j.jclepro.2020.122354

    Article  CAS  Google Scholar 

  4. W. Feng, Z. Feng, and L. Mao, Failure Analysis of a Secondary Driving Helical Gear in Transmission of Electric Vehicle, Eng. Fail. Anal., 2020, 117, p 104934. https://doi.org/10.1016/j.engfailanal.2020.104934

    Article  CAS  Google Scholar 

  5. T.J. Lisle, B.A. Shaw, and R.C. Frazer, External Spur Gear Root Bending Stress: A Comparison of ISO 6336:2006, AGMA 2101-D04, ANSYS Finite Element Analysis and Strain Gauge Techniques, Mech. Mach. Theory, 2017, 111, p 1–9. https://doi.org/10.1016/j.mechmachtheory.2017.01.006

    Article  Google Scholar 

  6. C. Dengo, G. Meneghetti, and M. Dabalà, Experimental Analysis of Bending Fatigue Strength of Plain and Notched Case-Hardened Gear Steels, Int. J. Fatigue, 2015, 80, p 145–161.

    Article  CAS  Google Scholar 

  7. G. Meneghetti, C. Dengo, and F. Lo Conte, Bending Fatigue Design of Case-Hardened Gears Based on Test Specimens, Proc. Inst. Mech. Eng. Part C J. Mech. Eng. Sci., 2018, 232(11), p 1953–1969.

    Article  Google Scholar 

  8. J. Kramberger, M. Šraml, I. Potrč, and J. Flašker, Numerical Calculation of Bending Fatigue Life of Thin-Rim Spur Gears, Eng. Fract. Mech., 2004, 71(4–6), p 647–656.

    Article  Google Scholar 

  9. K. Vučković, I. Galić, Ž Božić, and S. Glodež, Effect of Friction in a Single-Tooth Fatigue Test, Int. J. Fatigue, 2018, 114, p 148–158.

    Article  Google Scholar 

  10. H. Deng, Y. Guo, H. Liu, Q. Liu, Y. Guo, and H. Yu, Bending Fatigue Life Prediction Model of Carburized Gear Based on Microcosmic Fatigue Failure Mechanism, J. Mater. Eng. Perform., 2021 https://doi.org/10.1007/s11665-021-06236-8

    Article  Google Scholar 

  11. V. Savaria, F. Bridier, and P. Bocher, Predicting the Effects of Material Properties Gradient and Residual Stresses on the Bending Fatigue Strength of Induction Hardened Aeronautical Gears, Int. J. Fatigue, 2016, 85, p 70–84. https://doi.org/10.1016/j.ijfatigue.2015.12.004

    Article  Google Scholar 

  12. D.G. Lewicki and R. Ballarini, Effect of Rim Thickness on Gear Crack Propagation Path, J. Mech. Des. Trans. ASME, 1997, 119(1), p 88–95.

    Article  Google Scholar 

  13. Y. Wei and Y. Jiang, Fatigue Fracture Analysis of Gear Teeth Using XFEM, Trans. Nonferrous Met. Soc. China Engl. Ed., 2019, 29(10), p 2099–2108. https://doi.org/10.1016/S1003-6326(19)65116-2

    Article  Google Scholar 

  14. M.S. Raghav, A. Singh, and S. Patel, Fault Analysis of Spur Gear Using XFEM, Eng. Fail. Anal., 2022, 134, p 106060. https://doi.org/10.1016/j.engfailanal.2022.106060

    Article  Google Scholar 

  15. X. Zhang, L. Li, X. Qi, J. Zheng, X. Zhang, B. Chen, J. Feng and S. Duan, Experimental and Numerical Investigation of Fatigue Crack Growth in the Cracked Gear Tooth, Fatigue Fract. Eng. Mater. Struct., 2017, 40(7), p 1037–1047.

    Article  Google Scholar 

  16. R. Thirumurugan and N. Gnanasekar, Influence of Finite Element Model, Load-Sharing and Load Distribution on Crack Propagation Path in Spur Gear Drive, Eng. Fail. Anal., 2020, 110, p 104383. https://doi.org/10.1016/j.engfailanal.2020.104383

    Article  Google Scholar 

  17. A.M. Alshoaibi, Fatigue Crack Growth Analysis under Constant Amplitude Loading Using Finite Element Method, Materials (Basel), 2022, 15(8), p 2937.

    Article  CAS  Google Scholar 

  18. I. Čular, K. Vučković, S. Glodež and Z. Tonković, Computational Model for Bending Fatigue Prediction of Surface Hardened Spur Gears Based on the Multilayer Method, Int. J. Fatigue, 2022, 161, p 106892.

    Article  Google Scholar 

  19. Y. Dong, Y. Garbatov, and C. Guedes Soares, Fatigue Crack Initiation Assessment of Welded Joints Accounting for Residual Stress, Fatigue Fract. Eng. Mater. Struct., 2018, 41(8), p 1823–1837.

    Article  Google Scholar 

  20. F. Yin and A. Fatemi, Monotonic and Cyclic Deformations of Case-Hardened Steels Including Residual Stress Effects, Strain, 2011, 47(SUPPL. 1), p 74–83.

    Google Scholar 

  21. M.L. Roessle and A. Fatemi, Strain-Controlled Fatigue Properties of Steels and Some Simple Approximations, Int. J. Fatigue, 2000, 22(6), p 495–511.

    Article  CAS  Google Scholar 

  22. I. Čular, K. Vučković, D. Žeželj, and S. Glodež, Analytical Approach for Low and High Cycle Bending Fatigue Life Prediction of Carburized Gear Steel Specimens, Eng. Fail. Anal., 2020, 108, p 104328.

    Article  Google Scholar 

  23. K. Vučković, I. Čular, R. Mašović, I. Galić, and D. Žeželj, Numerical Model for Bending Fatigue Life Estimation of Carburized Spur Gears with Consideration of the Adjacent Tooth Effect, Int. J. Fatigue, 2021, 153, p 106515.

    Article  Google Scholar 

  24. A.M. Alshoaibi, Computational Simulation of 3D Fatigue Crack Growth under Mixed-Mode Loading, Appl. Sci., 2021, 11(13), p 5953.

    Article  CAS  Google Scholar 

  25. H. Ma, J. Zeng, R. Feng, X. Pang, Q. Wang, and B. Wen, Review on Dynamics of Cracked Gear Systems, Eng. Fail. Anal., 2015, 55, p 224–245. https://doi.org/10.1016/j.engfailanal.2015.06.004

    Article  Google Scholar 

  26. R. Citarella, V. Giannella, M. Lepore, and G. Dhondt, Dual Boundary Element Method and Finite Element Method for Mixed-Mode Crack Propagation Simulations in a Cracked Hollow Shaft, Fatigue Fract. Eng. Mater. Struct., 2018, 41(1), p 84–98.

    Article  Google Scholar 

Download references

Acknowledgments

This work was supported by the National Natural Science Foundation of China (51775315), China and Key Technology Research and Development Program of Shandong Province, China (2019JZZY010114).

Author information

Authors and Affiliations

  1. Key Laboratory of High Efficiency and Clean Mechanical Manufacture of MOE, School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Xianshun Sun, Jun Zhao, Zijian Zhang, Shaokang Song, Shaolei Gai & Yongliang Lu

  2. National Demonstration Center for Experimental Mechanical Engineering Education (Shandong University), Jinan, 250061, China

    Xianshun Sun, Jun Zhao, Zijian Zhang, Shaokang Song, Shaolei Gai & Yongliang Lu

  3. School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Xianshun Sun, Jun Zhao, Zijian Zhang, Shaokang Song, Shaolei Gai & Yongliang Lu

  4. Jinan Power Co. Ltd, China National Heavy Duty Truck Group Co. Ltd, Jinan, 250200, China

    Youbin Hu & Zhaoqin Liu

Authors
  1. Xianshun Sun
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Jun Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Youbin Hu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Zhaoqin Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Zijian Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Shaokang Song
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Shaolei Gai
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Yongliang Lu
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

XS: Conceptualization, writing—original draft. JZ: Conceptualization, writing—review and editing, project administration. YH: Supervision, project administration. ZL: Supervision, project administration. ZZ: Methodology. SS: Data curation, investigation. SG: Methodology. YL: Methodology.

Corresponding author

Correspondence to Jun Zhao.

Ethics declarations

Conflict of interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Sun, X., Zhao, J., Hu, Y. et al. The Prediction and Experimental Study of Bending Fatigue Life of Carburized Gears. J. of Materi Eng and Perform 33, 1051–1059 (2024). https://doi.org/10.1007/s11665-023-07999-y

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11665-023-07999-y

Keywords

Search

Navigation