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Interior fatigue of gears under special consideration of multiaxial stresses and local material properties

Interior fatigue in gears is a critical failure mode that significantly affects the performance and reliability of mechanical systems. This type of failure typically occurs along the gear tooth flank and is often driven by complex multiaxial stress states, including both operational loads and residual stresses introduced during case hardening. Multiaxial stresses in gears arise due to combined bending, shearing, and contact stresses, causing high localized stress concentrations at the surface and subsurface levels.

To assess the risk of interior fatigue of gears, the hardness- and residual stress profile, as well as material imperfections like nonmetallic inclusions and coarse grains need to be considered additionally to the multiaxial stress state, making the strength…

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Two prominent approaches to handle the multiaxial stresses are the critical plane approach and the integral stress approach. The critical plane approach focuses on identifying specific material planes where fatigue damage is most likely to initiate based on the maximum shear or normal stresses experienced by the material. It evaluates the orientation of stress components on these planes and accounts for damage accumulation, making it particularly effective for materials and conditions where crack initiation is controlled by localized stress or strain peaks. In contrast, the integral stress approach takes a more holistic view by integrating the entire stress tensor over a volume or surface to assess the overall fatigue damage. This method averages the effects of multiaxial stresses and considers the total energy or stress state, rather than focusing on a specific plane.

In the presentation a model based on critical plane approach [1] will be discussed and simulation results will be compared to gear fatigue tests. Starting point for the simulation model is a heat treatment simulation to derive the hardness and the residual stress profile after case hardening of the gears. The load-induced stresses are obtained by finite element simulation of the gear contact, and the strength under consideration of material defects is estimated using the methods of Murakami [2] in a probabilistic environment. The material data, especially the statistical distribution of nonmetallic inclusions gained by rotating bending fatigue testing and extreme values analysis will be explained. The comparison with the fatigue test data of gears focusses on the point of crack initiation, the crack orientation, size of critical defects and the fatigue endurance limit for 50% survival probability. Based on this comparison, the quality of the method is evaluated and proposals for further improvements are suggested.

[1] Probabilistic modelling of fatigue endurance strength of case-strengthened steels, Jean-André Meis, Dissertation RWTH Aachen, 2023

[2] Metal fatigue, effects of small defects and nonmetallic inclusions. Yukitaka Murakami, Elsevier, 2002

Artikelnummer: ICMFF14-2025-23

Titel: Interior fatigue of gears under special consideration of multiaxial stresses and local material properties
Autor(en): J.-A. Meis
DOI: 10.48447/ICMFF14-2025-23
Veranstaltung: 14. International Conference on Multiaxial Fatigue and Fracture 2025
Jahr der Veröffentlichung: 2025
Publikationsart: Tagungsmanuskript (PDF)
Sprache: Englisch
Stichwörter: Flank Fracture,Interior Fatigue,Critical Plane,Nonmetallic Inclusions,Probabilistic Design

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Crack Initiation Life Estimate for Notched Specimens of SUS304 and Mod.9Cr-1Mo Steels under Nonproportional Cyclic Loading

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1

Englisch

25,00 €

Nur online erhältlich Neu

Autor(en): N. M. Bauer, A. Wöhle, J. Baumgartner

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Unifying multiaxial fatigue life prediction of welded joints by considering support effects

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1

Englisch

25,00 €

Nur online erhältlich Neu

Autor(en): W. C. Hübsch, C. Gaier

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1

Englisch

25,00 €

Nur online erhältlich Neu

Autor(en): M. Müller, D. Knabner, L. Suchy, A. Hasse

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Effect of welding spots on the stress intensity and crack propagation angle under plain fretting and fretting fatigue with flat-flat contact

Publikationsart: Tagungsmanuskript (PDF)

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1

Englisch

25,00 €

Nur online erhältlich Neu

Autor(en): M.A. Meggiolaro, J. T.P. Castro, H. Wu

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A Maximum-Damage Critical Plane Formulation considering Peak Deviatoric Stress Effects

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1

Englisch

25,00 €

Nur online erhältlich Neu

Autor(en): A. Trapp, K. Rother

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Assessing Phase Relationships Between Stress Components in Statistical Fatigue Evaluations

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Englisch

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Autor(en): J. Albinmousa, A. Alhammali, M. Ismail

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The Use of Polar Damage Sum Concept for Calculating Mean Stress Effect in Multiaxial Fatigue Loading Conditions

Publikationsart: Tagungsmanuskript (PDF)

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Englisch

25,00 €

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Autor(en): A. Zaiat, A. Blug, G. Laskin, A. Bertz, F. Conrad, C. Kontermann, M. Oechsner

Systematic investigation of the influence of T-stress and LCF overloads in biaxially loaded cruciform specimen on plasticity-induced crack closure using digital image correlation

Publikationsart: Tagungsmanuskript (PDF)

Englisch

25,00 €

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Autor(en): N. B. Winther, M. L. Larsen, S. M. Jenson, J. H. Andreasen, J. Schjødt-Thomsen

Multiaxial Fatigue Testing of Welded Steel Joints Subjected to Non-Proportional Stress States Induced by Frequency Difference Between Normal and Shear Stresses

Publikationsart: Tagungsmanuskript (PDF)

Englisch

25,00 €

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Autor(en): G. A. Brito Oliveira, I. M. Matos, R. A. Cardoso, J. A. Araújo

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Englisch

25,00 €

Nur online erhältlich Neu