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The aim of our research is to clearly show the influence of defects on the bending fatigue strength of gear teeth. Carburized gears have many types of defects, such as non-martensitic layers, inclusions, tool marks, etc. It is well known that high strength gear teeth break from defects in their materials, so it’s important to know which defect limits the strength of a gear.
The quality of the material used for highly loaded critical gears is of primary importance in the achievement of their full potential. Unfortunately, the role which material defects play is not clearly understood by many gear designers. The mechanism by which failures occur due to material defects is often circuitous and not readily apparent. In general, however, failures associated with material defects show characteristics that point to the source of the underlying problem, the mechanism by which the failure initiated, and the manner in which it progressed to failure of the component.
The objective of this work is to introduce a method for the calculation of the tooth root load carrying capacity for gears, under consideration of the influence of the defect size on the endurance fatigue strength of the tooth root. The theoretical basis of this method is presented in this paper as well as the validation in running tests of helical and beveloid gears with different material batches, regarding the size distribution of inclusions. The torque level for a 50 percent failure probability of the gears is evaluated on the test rig and then compared to the results of the simulation. The simulative method allows for a performance of the staircase method that is usually performed physically in the back-to-back tests for endurance strength, as the statistical influence of the material properties is considered in the calculation model. The comparison between simulation and tests shows a high level of accordance.
Reduced component weight and ever-increasing power density require a gear design on the border area of material capacity. In order to exploit the potential offered by modern construction materials, calculation methods for component strength must rely on a deeper understanding of fracture and material mechanics in contrast to empirical-analytical approaches.
simplified equations for backlash and roll test center distance are derived. Unknown errors in measured tooth thickness are investigate. Master gear design is outlined, and an alternative to the master gear method is described. Defects in the test radius method are enumerated. Procedures for calculating backlash and for preventing significant errors in measurement are presented.