Abstract
Tooth flank fracture (TFF) is a critical fatigue failure mode in case-hardened gears, especially in large-scale and heavy-duty carburized gears. In this study, a TFF failed gear detached from wind turbine gearbox is examined. A contact model incorporating inhomogeneous inclusion and hardness gradient is developed based on semi-analytical method (SAM) and equivalent inclusion method (EIM). The risk of TFF is evaluated by considering a wide depth range of the material gradient properties and the site of inclusion by using material exposure theory. Results indicate that the increase of mean shear stress dominate the stress concentration around the inclusions. The risk of TFF rises dramatically once the inclusions present near the case-core interface. The higher core hardness is more effective to resist the stress concentration caused by inclusions.
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