Skip to main content
SpringerLink
Log in

Impacts of DLC and Cr-DLC coatings on noise level emitted during contact fatigue tests on AISI 4320 steel carburized gears

  • Technical Paper
  • Published:
Journal of the Brazilian Society of Mechanical Sciences and Engineering Aims and scope Submit manuscript

Abstract

Many efforts have been made to understand the impacts of the requirements brought by electrification to other powertrain subsystems than just the engine and battery, as several countries plan to ban the sale of gasoline and diesel-powered vehicles by 2030. The main requirement is the high rotation speed provided by electric motors when compared to combustion engines. Because of this large difference in rotational speed between these motor types, the gearing design to meet the requirements of electrification needs to be evaluated to be durable, efficient, and less noise pollution. This research presents an analysis of the pitting damaged area in spur gears based on experimental data obtained in a controlled fatigue test executed in a back-to-back test machine. The designed gear aimed to replicate in a gear bench test dynamic phenomenon with occurs on a referred first gear used in automotive transmission, based on contact stress magnitude. This work sought to correlate the impacts of diamond-like carbon (DLC) coating and a modified DLC coating with a metal-based layer (chromium nitride) on AISI 4320 steel carburized gears on noise level emitted during contact fatigue tests, as well as to evaluate the maximum daily exposure time that a person can be exposed to noise, without the use of personal protective equipment. The DLC coating showed the lowest average sound pressure levels among the investigated conditions (4.2 times smaller if compared with Cr-DLC coating or uncoated gears), which was attributed to the higher surface hardness and lower pitting damage.

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

References

  1. ISS ESG (2020) The future of mobility: Potential and ESG challenges of alternative drives

  2. Rego RR (2022) A call to the gear community: addressing residual stresses in design standards

  3. Robatto RB, Rego RR (2021) Engrenagens 4.0: As Super-Engrenagens na Indústria Automotiva do Futuro. Engrenagens Gears Magazine,pp 33–36

  4. Gomes CFS (2023) Gears for electromobility: A comparison between grinding and shaving routes. Dissertation of Master, Aeronautic Institute of Technology

  5. Gomes G de O (2023) The interaction between griding and isotropic superfinishing in the gear manufacturing. Dissertation of Master, Aeronautic Institute of Technology

  6. da Silva Neto MJ (2022) Design de engrenamento para requisitos da mobilidade elétrica. Trabalho de Conclusão de Curso, Instituto Tecnológico de Aeronáutica

  7. Harris O, Lanlois P, Gale A (2019) Electric Vehicle Whine Noise - Gear Blank Tuning as an Optimization Option. Gear Technology, pp 64–73

  8. Flodin A, Karlsson P (2013) Automotive Transmission Design Using Full Potential of Powder Metal. Gear Technology, pp 78–80

  9. Younes R, Hamzaoui N, Ouelaa N, Djebala A (2015) Perceptual study of the evolution of gear defects. Appl Acoust 99:60–67. https://doi.org/10.1016/j.apacoust.2015.05.010

    Article  Google Scholar 

  10. Geradts P, Brecher C, Löpenhaus C, Kasten M (2019) Reduction of the tonality of gear noise by application of topography scattering. Appl Acoust 148:344–359. https://doi.org/10.1016/j.apacoust.2018.12.039

    Article  Google Scholar 

  11. Rego RR, Brimmers J, Brecher C, Bergs T (2021) The Brazilian Gear Conference ITA-WZL, 1st ed. CCM-ITA, São José dos Campos

  12. Carranza Fernandez R, Tobie T, Collazo J (2022) Increase wind gearbox power density by means of IGS (Improved Gear Surface). Int J Fatigue 159:106789. https://doi.org/10.1016/j.ijfatigue.2022.106789

    Article  Google Scholar 

  13. Michaelis K, Höhn B, Hinterstoißer M (2011) Influence factors on gearbox power loss. Ind Lubrication Tribol 63:46–55. https://doi.org/10.1108/00368791111101830

    Article  Google Scholar 

  14. Fabra-Rodriguez M, Peral-Orts R, Campello-Vicente H, Campillo-Davo N (2021) Gear sound model for an approach of a mechanical acoustic vehicle alerting system (MAVAS) to increase EV’s detectability. Appl Acoust 184:108345. https://doi.org/10.1016/j.apacoust.2021.108345

    Article  Google Scholar 

  15. Kwon K, Seo M, Min S (2020) Efficient multi-objective optimization of gear ratios and motor torque distribution for electric vehicles with two-motor and two-speed powertrain system. Appl Energy 259:114190. https://doi.org/10.1016/j.apenergy.2019.114190

    Article  Google Scholar 

  16. Rajput D, Herreros JM, Innocente MS et al (2022) Impact of the number of planetary gears on the energy efficiency of electrified powertrains. Appl Energy 323:119531. https://doi.org/10.1016/j.apenergy.2022.119531

    Article  Google Scholar 

  17. Brecher C, Löpenhaus C, Knecht P (2016) Design of acoustical optimized bevel gears using manufacturing simulation. Procedia CIRP 41:902–907. https://doi.org/10.1016/j.procir.2015.12.103

    Article  Google Scholar 

  18. Dalcin RL, Marques de Menezes V, Fonseca Oliveira L et al (2022) Improvement on pitting wear resistance of gears by controlled forging and plasma nitriding. J Market Res 18:4698–4713. https://doi.org/10.1016/j.jmrt.2022.04.122

    Article  Google Scholar 

  19. Dalcin RL, de Menezes VM, da Silva RA et al (2023) Correlation between roughness, film thickness, and friction coefficient with pitting wear resistance of spur gears. Int J Adv Manuf Technol 129:5473–5492. https://doi.org/10.1007/s00170-023-12576-7

    Article  Google Scholar 

  20. Rego R (2016) Residual stress interaction in-between processes of the gear manufacturing chain. Doctorate Thesis, Aeronautic Institute of Technology

  21. Roozegar M, Angeles J (2018) Gear-shifting in a novel modular multi-speed transmission for electric vehicles using linear quadratic integral control. Mech Mach Theory 128:359–367. https://doi.org/10.1016/j.mechmachtheory.2018.06.010

    Article  Google Scholar 

  22. Wang F, Zhang J, Xu X et al (2019) New teeth surface and back (TSB) modification method for transient torsional vibration suppression of planetary gear powertrain for an electric vehicle. Mech Mach Theory 140:520–537. https://doi.org/10.1016/j.mechmachtheory.2019.06.018

    Article  Google Scholar 

  23. Qin Y, Tang X, Jia T et al (2020) Noise and vibration suppression in hybrid electric vehicles: state of the art and challenges. Renew Sustain Energy Rev 124:109782. https://doi.org/10.1016/j.rser.2020.109782

    Article  Google Scholar 

  24. Müller H, Gorgels C (2023) Aspects of Gear Noise, Quality, and Manufacturing Technologies for Electromobility. Gear Technology, pp 58–62

  25. Franco RR (2020) Gear contact fatigue failure effects evaluation under process uncertainty influence. Doctorate Thesis, University of São Paulo

  26. Mallipeddi D, Norell M, Sosa M, Nyborg L (2019) The effect of manufacturing method and running-in load on the surface integrity of efficiency tested ground, honed and superfinished gears. Tribol Int 131:277–287. https://doi.org/10.1016/j.triboint.2018.10.051

    Article  Google Scholar 

  27. Palma Calabokis O, Núñez de la Rosa YE, de Moraes SP et al (2022) Experimental and numerical study of contact fatigue for 18CrNiMo7-6 and 20MnCr5 carburized gear tooth. Surf Topogr Metrol Prop 10:034007. https://doi.org/10.1088/2051-672X/ac939f

    Article  Google Scholar 

  28. Muraro MA, Koda F, Reisdorfer U Jr, da Silva CH (2012) The influence of contact stress distribution and specific film thickness on the wear of spur gears during pitting tests. J Braz Soc Mech Sci & Eng 34:135–144. https://doi.org/10.1590/S1678-58782012000200005

    Article  Google Scholar 

  29. Moorthy V, Shaw BA (2012) Contact fatigue performance of helical gears with surface coatings. Wear 276–277:130–140. https://doi.org/10.1016/j.wear.2011.12.011

    Article  Google Scholar 

  30. Seabra J, Berthe D (1987) Influence of surface waviness and roughness on the normal pressure distribution in the hertzian contact. J Tribol 109:462–469. https://doi.org/10.1115/1.3261472

    Article  Google Scholar 

  31. Brandão JA, Martins R, Seabra JHO, Castro MJD (2014) Calculation of gear tooth flank surface wear during an FZG micropitting test. Wear 311:31–39. https://doi.org/10.1016/j.wear.2013.12.025

    Article  Google Scholar 

  32. Li X, Sosa M, Andersson M, Olofsson U (2016) A study of the efficiency of spur gears made of powder metallurgy materials – ground versus super-finished surfaces. Tribol Int 95:211–220. https://doi.org/10.1016/j.triboint.2015.11.021

    Article  Google Scholar 

  33. Fernandes PJL, McDuling C (1997) Surface contact fatigue failures in gears. Eng Fail Anal 4:99–107. https://doi.org/10.1016/S1350-6307(97)00006-X

    Article  Google Scholar 

  34. Ding Y, Rieger NF (2003) Spalling formation mechanism for gears. Wear 254:1307–1317. https://doi.org/10.1016/S0043-1648(03)00126-1

    Article  Google Scholar 

  35. Brandão JA, Martins R, Seabra JH, Castro MJ (2012) Surface damage prediction during an FZG gear micropitting test. In: Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology, 226, pp 1051–1073. https://doi.org/10.1177/1350650112461879

  36. Gans LHA, Guesser WL, Luersen MA, da Silva CH (2015) Numerical analysis of the influence of graphite nodule size on the pitting resistance of austepered ductile iron gears. Adv Mater Res 1120–1121:763–772. https://doi.org/10.4028/www.scientific.net/AMR.1120-1121.763

    Article  Google Scholar 

  37. Gunsel S, Korcek S, Smeeth M, Spikes HA (1999) The elastohydrodynamic friction and film forming properties of lubricant base oils. Tribol Trans 42:559–569. https://doi.org/10.1080/10402009908982255

    Article  Google Scholar 

  38. Zhao J, Sheng W, Li Z et al (2022) Effect of lubricant selection on the wear characteristics of spur gear under oil-air mixed lubrication. Tribol Int 167:107382. https://doi.org/10.1016/j.triboint.2021.107382

    Article  Google Scholar 

  39. Cardoso NFR, Martins RC, Seabra JHO et al (2009) Micropitting performance of nitrided steel gears lubricated with mineral and ester oils. Tribol Int 42:77–87. https://doi.org/10.1016/j.triboint.2008.05.010

    Article  Google Scholar 

  40. Martins RC, Cardoso NFR, Bock H et al (2009) Power loss performance of high pressure nitrided steel gears. Tribol Int 42:1807–1815. https://doi.org/10.1016/j.triboint.2009.03.006

    Article  Google Scholar 

  41. Zafosnik B, Glodez S, Ulbin M, Flasker J (2007) A fracture mechanics model for the analysis of micro-pitting in regard to lubricated rolling–sliding contact problems. Int J Fatigue 29:1950–1958. https://doi.org/10.1016/j.ijfatigue.2006.12.015

    Article  Google Scholar 

  42. Li K, Chen G, Liu D (2016) Study of the influence of lubrication parameters on gear lubrication properties and efficiency. ILT 68:647–657. https://doi.org/10.1108/ILT-06-2015-0089

    Article  Google Scholar 

  43. Rego R, Löpenhaus C, Gomes J, Klocke F (2018) Residual stress interaction on gear manufacturing. J Mater Process Technol 252:249–258. https://doi.org/10.1016/j.jmatprotec.2017.09.017

    Article  Google Scholar 

  44. Terrin A, Dengo C, Meneghetti G (2017) Experimental analysis of contact fatigue damage in case hardened gears for off-highway axles. Eng Fail Anal 76:10–26. https://doi.org/10.1016/j.engfailanal.2017.01.019

    Article  Google Scholar 

  45. Vera EE, Vite M, Lewis R et al (2011) A study of the wear performance of TiN, CrN and WC/C coatings on different steel substrates. Wear 271:2116–2124. https://doi.org/10.1016/j.wear.2010.12.061

    Article  Google Scholar 

  46. Saini BS, Gupta VK (2010) Effect of WC/C PVD coating on fatigue behaviour of case carburized SAE8620 steel. Surf Coat Technol 205:511–518. https://doi.org/10.1016/j.surfcoat.2010.07.022

    Article  Google Scholar 

  47. McMaster SJ, Liskiewicz TW, Neville A, Beake BD (2020) Probing fatigue resistance in multi-layer DLC coatings by micro- and nano-impact: correlation to erosion tests. Surf Coat Technol 402:126319. https://doi.org/10.1016/j.surfcoat.2020.126319

    Article  Google Scholar 

  48. Kapsiz M, Geffroy S, Holzer A, Schmitz K (2022) Tribological performances of diamond-like carbon coatings for hydraulic applications. Chem Eng Technol 46:118–127. https://doi.org/10.1002/ceat.202200459

    Article  Google Scholar 

  49. Abad MD, Muñoz-Márquez MA, El Mrabet S et al (2010) Tailored synthesis of nanostructured WC/a-C coatings by dual magnetron sputtering. Surf Coat Technol 204:3490–3500. https://doi.org/10.1016/j.surfcoat.2010.04.019

    Article  Google Scholar 

  50. Kuznetsova T, Lapitskaya V, Khabarava A et al (2023) Silicon addition as a way to control properties of tribofilms and friction of DLC coatings. Appl Surf Sci 608:155115. https://doi.org/10.1016/j.apsusc.2022.155115

    Article  Google Scholar 

  51. Gao M, Kim S-B, Li Y et al (2023) Triboelectric nanogenerator with enhanced output and durability based on Si-DLC films. Nano Energy 105:107997. https://doi.org/10.1016/j.nanoen.2022.107997

    Article  Google Scholar 

  52. Badiger PV, Desai V, Ramesh MR et al (2018) Effect of cutting parameters on tool wear, cutting force and surface roughness in machining of MDN431 alloy using Al and Fe coated tools. Mater Res Express 6:016401. https://doi.org/10.1088/2053-1591/aae2a3

    Article  Google Scholar 

  53. Badiger PV, Desai V, Ramesh MR et al (2018) Tribological behaviour of monolayer and multilayer Ti-based thin solid films deposited on alloy steel. Mater Res Express 6:026419. https://doi.org/10.1088/2053-1591/aaef6d

    Article  Google Scholar 

  54. Baydar N, Ball A (2003) Detection of gear failures via vibration and acoustic signals using wavelet transform. Mech Syst Signal Process 17:787–804. https://doi.org/10.1006/mssp.2001.1435

    Article  Google Scholar 

  55. Stadtfeld DHJ How Fast Fourier Transformations of single flank errors can be used during the development of a gearset to establish harmonic levels and side bands of quiet rolling gearsets.

  56. Moorthy V, Shaw BA (2013) An observation on the initiation of micro-pitting damage in as-ground and coated gears during contact fatigue. Wear 297:878–884. https://doi.org/10.1016/j.wear.2012.11.001

    Article  Google Scholar 

  57. Benedetti M, Fontanari V, Torresani E et al (2017) Investigation of lubricated rolling sliding behaviour of WC/C, WC/C-CrN, DLC based coatings and plasma nitriding of steel for possible use in worm gearing. Wear 378–379:106–113. https://doi.org/10.1016/j.wear.2017.02.029

    Article  Google Scholar 

  58. Xiao Y, Shi W, Luo J, Liao Y (2014) The tribological performance of TiN, WC/C and DLC coatings measured by the four-ball test. Ceram Int 40:6919–6925. https://doi.org/10.1016/j.ceramint.2013.12.015

    Article  Google Scholar 

  59. Liu H, Liu H, Zhu C, Zhou Y (2019) A review on micropitting studies of steel gears. Coatings 9:42. https://doi.org/10.3390/coatings9010042

    Article  Google Scholar 

  60. Sateesh Kumar C, Majumder H, Khan A, Patel SK (2020) Applicability of DLC and WC/C low friction coatings on Al2O3/TiCN mixed ceramic cutting tools for dry machining of hardened 52100 steel. Ceram Int 46:11889–11897. https://doi.org/10.1016/j.ceramint.2020.01.225

    Article  Google Scholar 

  61. Beake BD, Liskiewicz TW, Vishnyakov VM, Davies MI (2015) Development of DLC coating architectures for demanding functional surface applications through nano- and micro-mechanical testing. Surf Coat Technol 284:334–343. https://doi.org/10.1016/j.surfcoat.2015.05.050

    Article  Google Scholar 

  62. Wang L, Liu Y, Chen H, Wang M (2022) Modification methods of diamond like carbon coating and the performance in machining applications: a review. Coatings 12:224. https://doi.org/10.3390/coatings12020224

    Article  Google Scholar 

  63. Conde FF, Diaz JAÁ, da Silva GF, Tschiptschin AP (2019) Dependence of wear and mechanical behavior of nitrocarburized/CrN/DLC layer on film thickness. Mat Res 22:e20180499. https://doi.org/10.1590/1980-5373-mr-2018-0499

    Article  Google Scholar 

  64. Koda F (2009) Estudo da fadiga de contato em engrenagens cilíndricas de dentes retos. Dissertação de Mestrado, Universidade Tecnológica Federal do Paraná (UTFPR)

  65. DIN 14635–1 (2006) Gears – FZG test procedures – Part 1: FZG test method A/8.3/90 for relative scuffing load-carrying capacity of oils. Teil 3. Berlin: Deutsches Institut für Normung

  66. Chen T, Zhu C, Liu H et al (2022) Simulation and experiment of carburized gear scuffing under oil jet lubrication. Eng Fail Anal 139:106406. https://doi.org/10.1016/j.engfailanal.2022.106406

    Article  Google Scholar 

  67. Tuszynski W, Michalczewski R, Szczerek M, Kalbarczyk M (2012) A new scuffing shock test method for the determination of the resistance to scuffing of coated gears. Arch Civ Mechan Eng 12:436–445. https://doi.org/10.1016/j.acme.2012.08.003

    Article  Google Scholar 

  68. Feng K, Ni Q, Beer M et al (2022) A novel similarity-based status characterization methodology for gear surface wear propagation monitoring. Tribol Int 174:107765. https://doi.org/10.1016/j.triboint.2022.107765

    Article  Google Scholar 

  69. ASTM D341 (2003) Standard Test Method for Viscosity-Temperature Charts for Liquid Petroleum Products

  70. Tiryakiog M, Hudak D (2011) Guidelines for two-parameter weibull analysis for flaw-containing materials. Metall Mater Trans B 42:1130–1135. https://doi.org/10.1007/s11663-011-9556-8

    Article  Google Scholar 

  71. Abernethy R (2006) The new Weibull handbook, 5th ed. Dr. Robert. B. Abernethy, North Palm Beach

  72. Wollmann D, Soares GPPP, Grabarski MI et al (2017) Rolling contact fatigue failure mechanisms of plasma-nitrided ductile cast iron. J Materi Eng Perform 26:2859–2868. https://doi.org/10.1007/s11665-017-2717-4

    Article  Google Scholar 

  73. Reliasoft (2015) Life Data Analysis Reference

  74. Lin T, He Z (2017) Analytical method for coupled transmission error of helical gear system with machining errors, assembly errors and tooth modifications. Mech Syst Signal Process 91:167–182. https://doi.org/10.1016/j.ymssp.2017.01.005

    Article  Google Scholar 

  75. Troge J, Drossel W-G, Hensel E, et al (2016) Acoustical Optimization of a Train Gearbox Based on Overall System Simulation. In: International Congress and Exposition on Noise Control Engineering, INTER-NOISE 2016. Hamburg, Germany

  76. Uludamar E, Özcanli M, Çelebi K, Aydin K (2019) Investigating the noise generation of a compression ignition engine at different filters. Eur Mechan Sci 3:88–91. https://doi.org/10.26701/ems.564849

    Article  Google Scholar 

  77. Ballou G (2008) Handbook for sound engineers, 4th edn. Focal Press, Boston

    Google Scholar 

  78. Jiang JC, Meng WJ, Evans AG, Cooper CV (2003) Structure and mechanics of W-DLC coated spur gears. Surf Coat Technol 176:50–56. https://doi.org/10.1016/S0257-8972(03)00445-6

    Article  Google Scholar 

  79. Morita T, Inoue K, Ding X et al (2016) Effect of hybrid surface treatment composed of nitriding and DLC coating on friction-wear properties and fatigue strength of alloy steel. Mater Sci Eng A 661:105–114. https://doi.org/10.1016/j.msea.2016.03.015

    Article  Google Scholar 

  80. NR-15 (2022) Norma Regulamentadora No. 15 (NR-15) - Atividades e Operações Insalubres

Download references

Acknowledgements

The authors acknowledge the Fiat Chrysler Automobiles (FCA), Surface Phenomena Laboratory at the University of São Paulo, the Surface and Contact Laboratory, and the Multiuser Center for Material Characterization at UTFPR for the human support and laboratory structure.

Author information

Authors and Affiliations

  1. Department of Materials, Tribology and Surfaces, Federal University of Technology-Paraná, Curitiba, Paraná, Brazil

    Fernando Souza Roker da Silva & Carlos Henrique da Silva

  2. Department of Mechatronics and Mechanical Systems, University of São Paulo, São Paulo, Brazil

    Renato Ribeiro Franco

  3. Department of Mechanical Engineering, Horizontina College, Horizontina, Rio Grande Do Sul, Brazil

    Rafael Luciano Dalcin

Authors
  1. Fernando Souza Roker da Silva
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Renato Ribeiro Franco
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Rafael Luciano Dalcin
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Carlos Henrique da Silva
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Rafael Luciano Dalcin.

Additional information

Technical Editor: Aldemir Cavallini Jr.

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

da Silva, F.S.R., Franco, R.R., Dalcin, R.L. et al. Impacts of DLC and Cr-DLC coatings on noise level emitted during contact fatigue tests on AISI 4320 steel carburized gears. J Braz. Soc. Mech. Sci. Eng. 46, 389 (2024). https://doi.org/10.1007/s40430-024-04985-w

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s40430-024-04985-w

Keywords

Search

Navigation