Contact fatigue life prediction of a bevel gear under spectrum loading

doi:10.1007/s11465-019-0556-8

Front. Mech. Eng.

2020, Vol. 15

Issue (1) : 123-132 https://doi.org/10.1007/s11465-019-0556-8

RESEARCH ARTICLE

Contact fatigue life prediction of a bevel gear under spectrum loading

Pan JIA¹, Huaiju LIU¹(

), Caichao ZHU¹, Wei WU², Guocheng LU³

¹. State Key Laboratory of Mechanical Transmissions, Chongqing University, Chongqing 400044, China
². National Key Laboratory of Vehicular Transmission, Beijing Institute of Technology, Beijing 100081, China
³. Propulsion Development Department, Chongqing Changan New Energy Vehicles Technology, Chongqing 401133, China

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Abstract

Rolling contact fatigue (RCF) issues, such as pitting, might occur on bevel gears because load fluctuation induces considerable subsurface stress amplitudes. Such issues can dramatically affect the service life of associated machines. An accurate geometry model of a hypoid gear utilized in the main reducer of a heavy-duty vehicle is developed in this study with the commercial gear design software MASTA. Multiaxial stress–strain states are simulated with the finite element method, and the RCF life is predicted using the Brown–Miller–Morrow fatigue criterion. The patterns of fatigue life on the tooth surface are simulated under various loading levels, and the RCF S–N curve is numerically generated. Moreover, a typical torque–time history on the driven axle is described, followed by the construction of program load spectrum with the rain flow method and the Goodman mean stress equation. The effects of various fatigue damage accumulation rules on fatigue life are compared and discussed in detail. Predicted results reveal that the Miner linear rule provides the most optimistic result among the three selected rules, and the Manson bilinear rule produces the most conservative result.

Keywords bevel gear rolling contact fatigue (RCF) multiaxial fatigue criterion load spectrum damage accumulation rule

Corresponding Author(s): Huaiju LIU

Just Accepted Date: 04 November 2019 Online First Date: 09 December 2019 Issue Date: 21 February 2020

Cite this article:

Pan JIA,Huaiju LIU,Caichao ZHU, et al. Contact fatigue life prediction of a bevel gear under spectrum loading[J]. Front. Mech. Eng., 2020, 15(1): 123-132.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-019-0556-8
https://academic.hep.com.cn/fme/EN/Y2020/V15/I1/123

Fig.1 Calculation flow chart.

Tab.1 Basic parameters of a hypoid gear pair

Fig.2 Gleason hypoid gear pair studied in this work.

Fig.3 Finite element contact model of a gear pair.

Fig.4 Typical torque history of the output axle.

Fig.5 Torque mean amplitude frequency histogram.

Fig.6 Probability densities of mean torque and amplitude. (a) Torque amplitude frequency histogram; (b) torque amplitude probability density; (d) mean torque frequency histogram; (e) mean torque probability density.

Tab.2 The matrix of loading cycle under various amplitudes and mean values of torque

Tab.3 Eight-level standard load spectrum

Fig.7 Manson bilinear rule.

Fig.8 Distributions of contact pressure and von Mises at a torque of 500 N?m.

Fig.9 Contact fatigue life at various loading levels.

Fig.10 Evolutions of stress components during a loading cycle.

Fig.11 Contact fatigue S–N curve of driven gear.

Fig.12 Damage with two-stage loading under different criteria.

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