Skip to main content
SpringerLink
Log in

Investigations into non-metallic inclusion crack area characteristics relevant for tooth root fracture damages of case carburised and shot-peened high strength gears of different sizes made of high-quality steels

Untersuchungen zu Rissflächencharakteristiken nicht-metallischer Einschlüsse maßgeblich für Zahnfußbrüche von einsatzgehärteten und kugelgestrahlten hochtragfähigen Zahnrädern unterschiedlicher Größe aus hochreinen Stählen

  • Originalarbeiten/Originals
  • Published:
Forschung im Ingenieurwesen Aims and scope Submit manuscript

Abstract

Case carburised and shot-peened high-strength gears can fail by tooth root bending failures in the very high cycle fatigue range of the S‑N-curve due to crack initiation at a non-metallic inclusion. It is essential to understand crack characteristics and mechanisms of such sub-surface initiated cracks, which are different to surface initiated cracks, in order to further increase the gear performance. This paper discusses the results of detailed analyses of such fractured surfaces.

Zusammenfassung

Einsatzgehärtete und kugelgestrahlte hochtragfähige Zahnräder können im Zahnfuß im Wöhlerlinienbereich sehr hoher Lastwechsel aufgrund einer Rissinitiierung an nicht-metallischen Einschlüssen ausfallen. Es ist wichtig, die Risseigenschaften und -mechanismen solcher unter der Oberfläche initiierten Risse zu verstehen, welche sich von oberflächeninitiierten Rissen unterscheiden, um die Zahnradleistung weiter zu erhöhen. In dieser wissenschaftlichen Veröffentlichung werden die Ergebnisse detaillierter Analysen solcher gebrochenen Oberflächen behandelt.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

Abbreviations

NMI:

Non-metallic inclusion

ODA:

Optically dark area

GBF:

Granular bright face

FGA:

Fine granular area

RSA:

Rough surface area

ESR:

Electro-slag remelting

SEM:

Scanning electron microscope

MnCr:

Manganese-chromium

CrNiMo:

Chromium-nickel-molybdenum

dNMI [µm]:

Distance from the surface of the NMI

AFish-Eye [µm2]:

Area of the fish-eye

ANMI [µm2]:

Area of the NMI

CHD550HV [Mm]:

Case-hardening depth

lFish-Eye [µm]:

Length of the fish-eye

lNMI [µm]:

Length of the NMI

wFish-Eye [µm]:

Width of the fish-eye

wNMI [µm]:

Width of the NMI

References

  1. Shiozawa K, Murai M, Shimatani Y, Yoshimoto T (2010) Transition of fatigue failure mode of Ni–Cr–Mo low-alloy steel in very high cycle regime. Int J Fatigue 32(3):541–550

    Article  Google Scholar 

  2. ISO ISO 6336-3:2006. Calculation of load capacity of spur and helical gears—Part 3: Calculation of tooth bending strength

  3. DIN DIN 3990-3:1987. Tragfähigkeitsberechnung von Stirnrädern; Berechnung der Zahnfußtragfähigkeit

  4. Schurer S, Tobie T, Stahl K: Späte Zahnfußbrüche/Reinheitsgrad. Tragfähigkeitsgewinn im Zahnfuß durch hochreine Stähle. FVA-Nr. 293 III. FVA Abschlussbericht, Heft 1148. Frankfurt: Forschungsvereinigung Antriebstechnik e. V. (FVA) 2015

  5. Schurer S (2016) Einfluss nichtmetallischer Einschlüsse in hochreinen Werkstoffen auf die Zahnfußtragfähigkeit. TU München, Dissertation

    Google Scholar 

  6. Stenico A (2007) Werkstoffmechanische Untersuchungen zur Zahnfußtragfähigkeit einsatzgehärteter Zahnräder. TU München, Dissertation

    Google Scholar 

  7. Fuchs D, Schurer S, Tobie T, Stahl K: A model approach for considering non-metallic inclusions in the calculation of the local tooth root load carrying capacity of high-strength gears made of high-quality steels. In: Conference, O. C. G. (Hrsg.): Gears Conference, Lyon, 2018. Volumes 1 & 2. Oxford: Chartridge Books Oxford 2018, S. 645–655

  8. Fuchs D, Schurer S, Tobie T, Stahl K (2019) A model approach for considering nonmetallic inclusions in the calculation of the local tooth root load-carrying capacity of high-strength gears made of high-quality steels. Proc Inst Mech Eng Part C: J Mech Eng Sci 661:95440621984067

    Google Scholar 

  9. Murakami Y (2002) Metal fatigue. Effects of small defects and nonmetallic inclusions. Elsevier, Amsterdam

    Google Scholar 

  10. Murakami Y, Matsunaga H, Abyazi A, Fukushima Y (2013) Defect size dependence on threshold stress intensity for high-strength steel with internal hydrogen. Fatigue Fract Eng Mater Struct 36(9):836–850

    Article  Google Scholar 

  11. Sakai T, Li W, Lian B, Oguma N (2011) Review and new analysis on fatigue crack initiation mechanisms of interior inclusion-induced fracture of high strength steels in very high cycle regime. Proc Conf Vhcf 5:19–26.

    Google Scholar 

  12. Ochi Y, Matsumura T, Masaki K, Yoshida S (2002) High-cycle rotating bending fatigue property in very long-life regime of high-strength steels. Fatigue Fract Eng Mater Struct 25(8–9):823–830

    Article  Google Scholar 

  13. Wegst M, Wegst CW (2016) Stahlschlüssel. Key to Steel. Marbach: Verlag Stahlschlüssel Wegst GmbH

    Google Scholar 

  14. ISO 4967:1998. Steel-Determination of content of nonmetallic inclusions-Micrographic method using standard diagrams

  15. DIN ISO 14635-1:2006. FZG-Prüfverfahren A/8,3/90 zur Bestimmung der relativen Fresstragfähigkeit von Schmierölen

  16. DIN 51354 Teil 1:1990. Prüfung von Schmierstoffen; FZG-Zahnrad-Verspannungs-Prüfmaschine; Allgemeine Arbeitsgrundlagen

  17. Winkler KJ, Schurer S, Tobie T, Stahl K: Investigations on the Tooth Root Bending Strength and the Fatigue Fracture Characteristics of Case Carburized and Shot Peened Gears of Different Sizes. In: Conference, O. C. G. (Hrsg.): Gears Conference, Lyon, 2018. Volumes 1 & 2. Oxford: Chartridge Books Oxford 2018, S. 633–644

  18. Winkler KJ, Schurer S, Tobie T, Stahl K (2019) Investigations on the tooth root bending strength and the fatigue fracture characteristics of case-carburized and shot-peened gears of different sizes. Proc Inst Mech Eng Part C: J Mech Eng Sci. https://doi.org/10.1177/0954406219841650

    Article  Google Scholar 

  19. Juvonen P (2004) Effects of non-metallic inclusions on fatigue properties of calcium treated steels. Teknillisen korkeakoulun materiaalitekniikan laboratorion julkaisuja, 4/04. Espoo: Helsinki University of. Technology (Singap World Sci). ISBN: 951-22-7423-X

  20. Burkart K (2009) Überrollungslebensdauer des Wälzlagerstahls 100Cr6 in Abhängigkeit von nicht idealen Gefügeausbildungen unter besonderer Berücksichtigung der Karbidzeiligkeit. Universität Bremen, Dissertation

    Google Scholar 

  21. ASTM E45—13:2013-01. Standard Test Methods for Determining the Inclusion Content of Steel

  22. SEP 1571:2017-08. Bewertung von Einschlüssen in Edelstählen auf Basis der Einschlussflächen – Teil 1: Grundlagen

  23. Yang ZG, Zhang JM, Li SX, Li GY, Wang QY, Hui WJ, Weng YQ (2006) Crit Inclusion Size High Strength Steels Under Ultra-high Cycle Fatigue Mater Sci Eng A 427(1–2):167–174

    Google Scholar 

  24. Bretl N, Schurer S, Tobie T, Stahl K, Höhn B‑R (2013) Investigations on Tooth Root Bending Strength of Case Hardened Gears in the Range of High Cycle. Fatigue Agma Tech Pap 13FT:M9

    Google Scholar 

  25. Bretl NT, Tobie T, Höhn B-R: Späte Zahnfußbrüche. Zahnfußbruch mit Rissausgang unter der Oberfläche an einsatzgehärteten Zahnrädern. FVA-Nr. 293 II. FVA Abschlussbericht, Heft 851. Frankfurt: Forschungsvereinigung Antriebstechnik e. V. (FVA) 2008

Download references

Acknowledgements

This research work was equally funded by the “Arbeitsgemeinschaft industrieller Forschungsvereinigungen e. V. (AiF)”, the German Federal Ministry of Economics and Technology (BMWi, IGF no. 16662N) and the “Forschungsvereinigung Antriebstechnik e. V. (FVA)”. The results shown in this work were taken from the research project FVA 293 III “Späte Zahnfußbrüche/Reinheitsgrad” [4] and [5]. Former research work [6, 24, 25] was funded inter alia by the “Arbeitsgemeinschaft industrieller Forschungsvereinigungen e. V. (AiF)”, “Forschungsgemeinschaft der Eisen und Metall verarbeitenden Industrie e. V. (AVIF)” and/or the “Forschungsvereinigung Antriebstechnik e. V. (FVA)”. More detailed information on the influence of non-metallic inclusions is given in the final reports.

figure f
figure g
figure h
figure i

Author information

Authors and Affiliations

  1. Institute of Machine Elements, Gear Research Centre (FZG), Technical University of Munich, Boltzmannstraße 15, 85748, Garching b. Munich, Germany

    D. Fuchs, T. Tobie & K. Stahl

  2. MAN Truck & Bus AG, Munich, Germany

    S. Schurer

Authors
  1. D. Fuchs
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. S. Schurer
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. T. Tobie
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. K. Stahl
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to D. Fuchs.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Fuchs, D., Schurer, S., Tobie, T. et al. Investigations into non-metallic inclusion crack area characteristics relevant for tooth root fracture damages of case carburised and shot-peened high strength gears of different sizes made of high-quality steels. Forsch Ingenieurwes 83, 579–587 (2019). https://doi.org/10.1007/s10010-019-00324-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s10010-019-00324-x

Search

Navigation