Abstract
In order to determine the surface durability of case-hardened gears and the optimum design conditions required to prevent spalling fatigue, an analytical model was developed which correlates the subsurface shear stress produced by the transmitted load with the material strength of the gear. Consequently, it was made clear that there is an optimum case depth for the required surface durability and that the crack initiation depth of spalling coincides quite well with the depth where the subsurface shear stress exceeds the material shear strength. The implications of the model for optimizing the carburizing process and preventing gear spalling fatigue are discussed.
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