Abstract
In this paper, a numerical model is proposed to predict the location and the number of cycles for bending fatigue failure of surface-hardened gears. The predictions are validated against experimental results. Linear-elastic stresses and strains obtained by a finite element simulation are imported into the fatigue model. Bending fatigue lives at the observed tooth root region are estimated based on the multilayer method, hardness method, and strain-life approach. The critical plane approach is employed due to non-proportional loading. Good agreement between actual and predicted bending fatigue lives was observed, as well as between the estimated and actual subsurface failure location.
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