Abstract
Surface integrity parameters exert an enormous function on contact fatigue performance of gears. In this paper, a gear contact fatigue life prediction model that incorporates surface integrity parameters is proposed. The micropitting and pitting damage of failed gears are quantitatively analyzed through micro-characterization techniques. A three-dimensional contact analysis of rough surface is performed to simulate the morphology evolution during gear running-in. And the coupling effect of residual stress and rough morphology on the contact stress field and fatigue life is analyzed. Finally, residual stress optimization design is carried out based on the failed gear. Gears subjected to shot peening are designed and gear contact fatigue tests under various working conditions are performed. The research results indicate that the plastic deformation at the asperities level in the running-in process mainly occurs during the initial loading. The fatigue life significantly increases by improving the residual stress distribution on the tooth surface through shot peening process. The maximum relative error between predicted fatigue life and measured fatigue life is less than 20%, which effectively verifies the accuracy of the proposed model. The technique presented in this study could provide theoretical basis and data support for the anti-fatigue design and manufacturing of gears.
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