An Experimental Evaluation of Cumulative Damage in Gear Single Tooth Bending Fatigue
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Date
2023-12
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Publisher
The Ohio State University
Abstract
Tooth bending fatigue failure is a primary design concern for gear designers in power transmission applications. Fracture of a gear tooth in operation results in overload conditions to adjacent teeth which cascades into catastrophic failure of the entire power transmission system. While standard constant stress amplitude fatigue evaluations are common to experimentally determine probabilistic stress life (P-S-N) relationships, they do not directly measure the fatigue lives under complex, non-constant amplitude loading scenarios applied to gears in most applications. Various cumulative damage models exist to estimate fatigue life under duty cycle loading but their accuracy is both material and stress state dependent. Most of these empirical models are originated from uniaxial stress states and for limited materials. There is a void of experimental data which precludes the evaluation of cumulative damage model accuracy for gear tooth bending fatigue in typical case carburized gear steels. This research study conducts a standard fatigue evaluation along with six sets of dual stress amplitude single tooth bending fatigue tests to empirically determine the effects of multi-stage loading. Various cumulative damage fatigue models are then employed to estimate the fatigue lives of the dual stress amplitude specimens and the accuracy of each model is assessed.
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Keywords
Fatigue, Reliability Engineering, Cumulative Damage, Gearbox Reliability