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Rim Thickness Effects on Gear Crack Propagation Life

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Abstract

Analytical and experimental studies were performed to investigate the effect of gear rim thickness on crack propagation life. The FRANC (FRacture ANalysis Code) computer program was used to simulate crack propagation. The FRANC program used principles of linear elastic fracture mechanics, finite element modeling, and a unique re-meshing scheme to determine crack tip stress distributions, estimate stress intensity factors, and model crack propagation. Various fatigue crack growth models were used to estimate crack propagation life based on the calculated stress intensity factors. Experimental tests were performed in a gear fatigue rig to validate predicted crack propagation results. Test gears were installed with special crack propagation gages in the tooth fillet region to measure bending fatigue crack growth. Good correlation between predicted and measured crack growth was achieved when the fatigue crack closure concept was introduced into the analysis. As the gear rim thickness decreased, the compressive cyclic stress in the gear tooth fillet region increased. The retarded crack growth and increased the number of crack propagation cycles to failure.

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Authors and Affiliations

  1. Vehicle Propulsion Directorate, U.S. Army Research Laboratory, NASA Lewis Research Center, Cleveland, OH, 44135

    David G. Lewicki

  2. Department of Civil Engineering and of Mechanical & Aerospace Engineering, Case Western Reserve University, Cleveland, OH, 44106-7201

    Roberto Ballarini

Authors
  1. David G. Lewicki
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  2. Roberto Ballarini
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Lewicki, D.G., Ballarini, R. Rim Thickness Effects on Gear Crack Propagation Life. International Journal of Fracture 87, 59–86 (1997). https://doi.org/10.1023/A:1007368801853

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