Reliable Gear Design: Translation of the Results of Single Tooth Bending Fatigue Tests Through the Combination of Numerical Simulations and Fatigue Criteria

Concli, Franco; Maccioni, Lorenzo; Bonaiti, Luca

doi:10.2495/cmem210101

Cited by 11 publications

(10 citation statements)

References 20 publications

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“…In recent studies, the authors pointed out that the FE simulation results of the STBF configuration can be analyzed and elaborated via different fatigue criteria based on the critical plane approach [41][42][43]. These allow for evaluating the criticality of each point along the ρ f P .…”

Section: Introductionmentioning

confidence: 99%

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Early Crack Propagation in Single Tooth Bending Fatigue: Combination of Finite Element Analysis and Critical-Planes Fatigue Criteria

Concli

Maccioni

Fraccaroli

et al. 2021

Metals

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Mechanical components, such as gears, are usually subjected to variable loads that induce multiaxial non-proportional stress states, which in turn can lead to failure due to fatigue. However, the material properties are usually available in the forms of bending or shear fatigue limits. Multiaxial fatigue criteria can be used to bridge the gap between the available data and the actual loading conditions. However, different criteria could lead to different results. The main goal of this paper is to evaluate the accuracy of different criteria applied to real mechanical components. With respect to this, five different criteria based on the critical plane concept (i.e., Findley, Matake, McDiarmid, Papadopoulos, and Susmel) have been investigated. These criteria were selected because they not only assess the level of damage, but also predict the direction of crack propagation just after nucleation. Therefore, measurements (crack position and direction) on different fractured gear samples tested via Single Tooth Bending Fatigue (STBF) tests on two gear geometries were used as reference. The STBF configuration was numerically simulated via Finite Elements (FE) analyses. The results of FE were elaborated based on the above-mentioned criteria. The numerical results were compared with the experimental ones. The result of the comparison showed that all the fatigue criteria agree in identifying the most critical point. The Findley and Papadopulus criteria proved to be the most accurate in estimating the level of damage. The Susmel criterion turns out to be the most conservative one. With respect to the identification of the direction of early propagation of the crack, the Findley criterion revealed the most appropriate.

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Section: Introductionmentioning

confidence: 99%

“…Moreover, it permits to individuate the potential propagation direction of the crack after nucleation. Nevertheless, it has been observed that different fatigue criteria could lead to different results in terms of TBS and/or crack propagation direction [42].…”

Section: Introductionmentioning

confidence: 99%

Early Crack Propagation in Single Tooth Bending Fatigue: Combination of Finite Element Analysis and Critical-Planes Fatigue Criteria

Concli

Maccioni

Fraccaroli

et al. 2021

Metals

Self Cite

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show abstract

“…Material Design & Processing Communications case and the actual case [23, 36-39, 52, 53]. On the one hand, the lack of the rolling/sliding condition implies that the loading condition occurring within the toot root is different [11,54,55]. On the other hand, the fact that the tests are performed on the teeth rather that gear implies a statistical difference [17,18].…”

Section: Gear Testing For Tooth Root Bending Fatiguementioning

confidence: 99%

Gear Tooth Root Bending Strength Estimation under the Assumption of Fatigue Limit Existence

Bonaiti

Gorla

2022

Material Design & Processing Communications

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Being able to properly predict gear failure is a key aspect to achieve a reliable light-weight gearbox. Among the several gear failures, tooth root bending fatigue is considered as the most dangerous one because it implies the stoppage of the whole gearbox. In order to characterize a gear for this phenomena, Single Tooth Bending Fatigue (STBF) tests are the most performed ones. However, as in STBF test THERE IS no sliding/rolling contact and as the specimens are teeth rather than gears, some differences occur between the test conditions and those of the real case. This paper deals with the statistical ones that is the estimation of the gear SN curve starting from the teeth one. The teeth SN curve has been estimated by means of a statistical model developed considering Murakami’s idea of nonpropagating crack. Then, a methodology based on statistic of extreme is adopted for the purpose of estimating the gear SN curve.

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“…By considering the modal parameters of the structures and the influence of structural dynamic characteristics on micro-structural deformation, the factors that influence vibration fatigue damages were studied. Concli, F. [ 17 ] studied the different fatigue criteria according to different results of crack propagation direction. Poursaeidi and Arhani [ 18 ] investigated the failure of an auxiliary steam turbine.…”

Section: Introductionmentioning

confidence: 99%

Experimental Study on Vibration Fatigue Behavior of Aircraft Aluminum Alloy 7050

2022

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It has been previously noted that the development of aerospace material technology and breakthroughs are inseparable when obtaining great achievements in the aerospace industry. Materials are the basis and precursor of modern high technology and industry. As one of the most powerful aluminium alloys, 7050 is widely used in the aerospace field. In this manuscript, the vibration fatigue behaviour of aircraft aluminium alloy 7050 is studied based on experiments. A vibration fatigue experiment and the traditional fatigue testing of aluminium alloy 7050 were performed. We found that there was an extreme difference between the vibration fatigue and the traditional fatigue curves. In addition, the experimental end criteria for the vibration fatigue experiment of aluminium alloy 7050 was obtained from the acceleration reduction and the frequency reduction value. For the acceleration experimental end criterion, 2% was the acceleration reduction value for the vibration fatigue experimental end criteria of aluminium alloy 7050. For the frequency experimental end criterion, 2% was the frequency reduction value for the vibration fatigue experimental end criteria of aluminium alloy 7050.

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Reliable Gear Design: Translation of the Results of Single Tooth Bending Fatigue Tests Through the Combination of Numerical Simulations and Fatigue Criteria

Cited by 11 publications

References 20 publications

Early Crack Propagation in Single Tooth Bending Fatigue: Combination of Finite Element Analysis and Critical-Planes Fatigue Criteria

Early Crack Propagation in Single Tooth Bending Fatigue: Combination of Finite Element Analysis and Critical-Planes Fatigue Criteria

Gear Tooth Root Bending Strength Estimation under the Assumption of Fatigue Limit Existence

Experimental Study on Vibration Fatigue Behavior of Aircraft Aluminum Alloy 7050

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