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Description
This study investigates surface contact fatigue crack propagation in spur gears subjected to rolling-sliding contact using the Finite Element Method (FEM). The extended Finite Element Method (XFEM) with an energy-based damage evolution criterion was employed to simulate mixed-mode crack propagation. The influence of key parameters, including applied torques of 132, 199, and 265 Nm and friction coefficients of 0.1, 0.2, and 0.3, was analyzed. Particular attention was given to the distribution of von Mises stress, contact pressure, and the effect of lubrication pressure on crack faces. Hertzian contact theory was used to define the elliptical contact parameters; while a 2D plane stress model was adopted assuming initial crack formation at the gear tooth root. Pre-alloyed steel properties suitable for light-duty transmission systems were utilized. Results show that decreasing the friction coefficient at the crack face (0.04, 0.10, and 0.15) significantly promotes crack growth due to the penetration of lubricating pressure. The highest equivalent stress occurs near the surface, and lower friction values lead to longer crack lengths. The numerical predictions demonstrate good agreement with experimental data from literature, providing valuable insights into fatigue crack behavior in spur gears under rolling-sliding conditions.
| Topic Area | Fatigue, Corrosion and Structural Integrity of Engineering Structures and Mechanical Systems |
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