Abstract
The surface hardness and residual stress (RS) states significantly affect gear bending fatigue, and further mainly determines the reliability of the high-end equipment such as helicopters and electric automobiles. To date, there has been limited research focusing on the study of the quantitative connection between fatigue life and such surface integrity characteristics. In this paper, a damage-coupled gear bending fatigue model based on the continuum damage theory is established to calculate the gear fatigue life considering RS and hardness states. Then, unified gear bending stress-life (S-N) equations originating from the Basquin equation are derived to evaluate the quantitative effects of RS and hardness on gear bending fatigue life. The RS and hardness impact coefficients in unified equations are determined using the fatigue data obtained from a gear damage-coupled model. The unified gear bending S-N curves are verified using the experimental fatigue life data of shot peening and un-peening gears. These lead to the establishment of the unified equation integrating both the residual stress and surface hardness states for 18CrNiMo7-6 gear.
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