Abstract
Rolling contact fatigue (RCF) issues, such as pitting, might occur on bevel gears because load fluctuation induces considerable subsurface stress amplitudes. Such issues can dramatically affect the service life of associated machines. An accurate geometry model of a hypoid gear utilized in the main reducer of a heavy-duty vehicle is developed in this study with the commercial gear design software MASTA. Multiaxial stress—strain states are simulated with the finite element method, and the RCF life is predicted using the Brown–Miller–Morrow fatigue criterion. The patterns of fatigue life on the tooth surface are simulated under various loading levels, and the RCF S–N curve is numerically generated. Moreover, a typical torque—time history on the driven axle is described, followed by the construction of program load spectrum with the rain flow method and the Goodman mean stress equation. The effects of various fatigue damage accumulation rules on fatigue life are compared and discussed in detail. Predicted results reveal that the Miner linear rule provides the most optimistic result among the three selected rules, and the Manson bilinear rule produces the most conservative result.
Highlights
Bevel gears have been extensively used in main reducers and differentials of automobiles, aerospace devices, and printing devices due to their high mechanical efficiency, large loading capacity, low noise behavior, and capability for direct power transmission between two orthogonal shafts
The prediction of rolling contact fatigue (RCF) life of a bevel gear pair is imperative for reliability evaluation
Niemann et al [1] developed the first version of FZG gear test rig and defined relevant experimental standards. This type of test rig was extensively applied in fatigue and tribological studies on involute parallel gears [2]. He et al [3] investigated the effect of external load on involute gear contact fatigue life and curve-fitted the stress–life formula on the basis of numerical data
Summary
Bevel gears have been extensively used in main reducers and differentials of automobiles, aerospace devices, and printing devices due to their high mechanical efficiency, large loading capacity, low noise behavior, and capability for direct power transmission between two orthogonal shafts. This type of test rig was extensively applied in fatigue and tribological studies on involute parallel gears [2] He et al [3] investigated the effect of external load on involute gear contact fatigue life and curve-fitted the stress–life formula on the basis of numerical data. Mayer et al [21] investigated the effect of cyclic loads below the endurance limit on fatigue damage in a series of variable amplitude loads According to these previous studies, accurate fatigue life estimation of bevel gears depends on the following prerequisites: Fatigue S–N curve, load spectrum, and proper fatigue damage accumulation rule. A few studies on bevel gear fatigue life have considered these factors To address this shortage, this study used the finite element method to simulate the multiaxial stress–strain states of subsurface material points and the RCF S–N curve of bevel gear.
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