Analogy test rig for the generation of tooth flank fractures at large gears (WZL-double pulsator)—commissioning and first test results

Abstract

As a result of the enhanced of load-carrying capacity with regard to pitting and tooth root breakage, generation of tooth flank fractures became more frequent. This type of damage differs from existing fatigue damages on the tooth flank in that crack initiation takes place below the case hardened surface layer and the tooth breaks in the area of the active tooth flank. An isolated investigation of tooth flank fractures is currently not possible because there is no analogy test rig available that can reproduce both, the compressive stress due to Hertzian contact flattening as well as the tensile stress due to tooth bending. For this reason, a test rig concept is being developed, manufactured and put into operation in the DFG research project “Analogy test rig for tooth flank fractures”, which allows the generation of tooth flank fractures in absence of other damage types. This report deals with the commissioning of the WZL-Double Pulsator as well as first test results. The FE model of the analogy test rig is validated by measuring tooth root strains with strain gauges and comparing them with the calculated strains. Finally, the commissioning is carried out and first tests are performed.