Surface initiated tooth flank damage. Part II: Prediction of micropitting initiation and mass loss

Brandão, José A.; Seabra, Jorge; Castro, J.

doi:10.1016/j.wear.2009.07.020

Cited by 34 publications

(26 citation statements)

References 5 publications

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“…Other numerical approaches for prediction of micropitting in gear teeth include those of Brandão et al [11,12] and Li and Kahraman [13][14][15]. Evans et al [16] use a mixed lubrication model to predict the micropitting damage accumulation during a single mesh cycle in a pair of helical gears.…”

Section: Introductionmentioning

confidence: 99%

Prediction of micropitting damage in gear teeth contacts considering the concurrent effects of surface fatigue and mild wear

Morales-Espejel

Rycerz

Kadiric

2018

Wear

135

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A B S T R A C TThe present paper studies the occurrence of micropitting damage in gear teeth contacts. An existing general micropitting model, which accounts for mixed lubrication conditions, stress history, and fatigue damage accumulation, is adapted here to deal with transient contact conditions that exist during meshing of gear teeth. The model considers the concurrent effects of surface fatigue and mild wear on the evolution of tooth surface roughness and therefore captures the complexities of damage accumulation on tooth flanks in a more realistic manner than hitherto possible. Applicability of the model to gear contact conditions is first confirmed by comparing its predictions to relevant experiments carried out on a triple-disc contact fatigue rig. Application of the model to a pair of meshing spur gears shows that under low specific oil film thickness conditions, the continuous competition between surface fatigue and mild wear determines the overall level as well as the distribution of micropitting damage along the tooth flanks. The outcome of this competition in terms of the final damage level is dependent on contact sliding speed, pressure and specific film thickness. In general, with no surface wear, micropitting damage increases with decreasing film thickness as may be expected, but when some wear is present micropitting damage may reduce as film thickness is lowered to the point where wear takes over and removes the asperity peaks and hence reduces asperity interactions. Similarly, when wear is negligible, increased sliding can increase the level of micropitting by increasing the number of asperity stress cycles, but when wear is present, an increase in sliding may lead to a reduction in micropitting due to faster removal of asperity peaks. The results suggest that an ideal situation in terms of surface damage prevention is that in which some mild wear at the start of gear pair operation adequately wears-in the tooth surfaces, thus reducing subsequent micropitting, followed by zero or negligible wear for the rest of the gear pair life. The complexities of the interaction between the contact conditions, wear and surface fatigue, as evident in the present results, mean that a full treatment of gear micropitting requires a numerical model along the lines of that applied here, and that use of overly simplified criteria may lead to misleading predictions.

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Section: Introductionmentioning

confidence: 99%

Prediction of micropitting damage in gear teeth contacts considering the concurrent effects of surface fatigue and mild wear

Morales-Espejel

Rycerz

Kadiric

2018

Wear

135

View full text Add to dashboard Cite

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“…One of their key results was that the lowest film thickness occurred because of surface valleys, which helped the lubricant oil to escape between the contact surfaces in the transverse direction. Brandão et al [17] presented a numerical model and compared with a FZG testing of gear surface-initiated damages, to predict the micropitting and gear tooth wear loss. The predictions and measurement of wear losses were correlated, but the surface roughness results did not match well.…”

Section: Review Of Recent Micropitting Researchmentioning

confidence: 99%

Experimental and analytical study of gear micropitting initiation and propagation under varying loading conditions

Al-Tubi

Long

Zhang³

et al. 2015

Wear

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Micropitting damage is one of the failure modes commonly observed in gears leading to destructive failures, which in turn results in unplanned shutdown and expensive replacement, such as those observed in wind turbine gearboxes. This study investigates gear micropitting initiation and propagation when subjected to varying torque loads under a constant rotational speed. The study employs both experimental gear testing and analytical evaluation based on the ISO Technical Report of Gear Micropitting, ISO/TR 15144-1:2010 and the recently revised ISO/TR 15144-1:2014. Initiation and propagation of micropitting are assessed in testing by quantifying the development of micropits and their progressive rate after specific numbers of running cycles at step-up torque levels. The analytical study is conducted to validate the prediction of micropitting using the ISO/TR recommended procedures by comparing the results with the occurrence of micropits in the tested gears.The gear test results show that micropitting initiates at the pinion dedendum but escalates at the addendum, because of the greater severity of progressive micropitting at the dedendum of the mating wheel where the tip relief area first comes into mesh. The analytical results, based on varying surface roughness measurements obtained from the tested gears, confirm that the maximum contact stresses and minimum specific lubricant film thicknesses occur in these regions. The specific lubricant film thickness varies considerably because of changes of surface roughness after gears are subjected to various running cycles under varying torque levels. It has found that the excessive loading, gear tooth micro-geometry, surface roughness and lubricant film thickness are the main factors affecting micropitting.

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“…As can be observed, the model is comprised of two great blocks: one for the calculation of the elastic stresses at each instant of the meshing of the gears and another for the application of the Dang-Van high cycle fatigue initiation model to each point within the depth of 30 µm inside the tooth surface. It is not within the scope of this document to explain the model in detail, which is fully exposed in [4]. Instead, the readers attention is directed to several elements that must be provided if the model is to have adequate accuracy:…”

Section: Numerical Modelmentioning

confidence: 99%

“…The first through third item are resolved through measurement. In particular, the third item is pointed to the reader's attention because it was the source of some uncertainty in [4] that [5] has dispelled. As for the remaining items, as well as the actual fatigue initiation criterion, they will be briefly discussed in what follows for the convenience of the reader.…”

Section: Numerical Modelmentioning

confidence: 99%

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Gear micropitting: model and validation

Brandão

Seabra

Castro

2010

Tribology and Design

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A numerical model for the prediction of surface initiated damage on gear tooth flanks (micropitting and mild wear) is presented. This model hinges on a model of the mixed film lubrication regime and on the application of the Dang Van highcycle multi-axial fatigue criterion. The numerical model developed was applied to the prediction of micropitting and mass loss of gear teeth in an actual micropitting test.

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Surface initiated tooth flank damage. Part II: Prediction of micropitting initiation and mass loss

Cited by 34 publications

References 5 publications

Prediction of micropitting damage in gear teeth contacts considering the concurrent effects of surface fatigue and mild wear

Prediction of micropitting damage in gear teeth contacts considering the concurrent effects of surface fatigue and mild wear

Experimental and analytical study of gear micropitting initiation and propagation under varying loading conditions

Gear micropitting: model and validation

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