Abstract
• Additional gear finishing methods such as shot peening (SP), superfinishing (SF), and their combination (IGS) significantly increase gear capacity, but these effects have not yet been adequately considered in standards. • Potential increases of safety margins above 1.2 both for pitting and bending strength can be obtained by means of IGS, based on experimental results. • Additional fatigue tests are needed to confirm IGS benefits in the wind sector, since size plays a significant role and wind gear sizes are quite far from standard. Increasing gearbox power density is a key factor in reducing the levelized cost of wind energy (LCOE). The tooth root and flank load carrying capacity of gears are strongly affected by surface conditions. Additional finishing methods such as shot peening (SP) and superfinishing (SF) significantly increase the gear load capacity, but these effects have not yet been adequately considered in the current ISO 6336 standard or in any other gear standards. Based on the experimental results, an estimation of the safety margin increase is calculated for a wind gearbox part. Additional fatigue tests are needed to confirm this increase.
Published Version
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