Simulation of the fatigue-wear coupling mechanism of an aviation gear
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ISSN 2223-7690 CN 10-1237/TH
RESEARCH ARTICLE
Simulation of the fatigue-wear coupling mechanism of an aviation gear Boyu ZHANG1, Huaiju LIU1,*, Caichao ZHU1, Yibo GE2 1
State Key Laboratory of Mechancial Transmissions, Chongqing University, Chongqing 400044, China
2
Shanghai Peentech Equipment Tech. Co. Ltd., Shanghai 201800, China
Received: 31 March 2020 / Revised: 09 July 2020 / Accepted: 21 August 2020
© The author(s) 2020. Abstract: The contact fatigue of aviation gears has become more prominent with greater demands for heavy‐duty and high‐power density gears. Meanwhile, the coexistence of tooth contact fatigue damage and tooth profile wear leads to a complicated competitive mechanism between surface‐initiated failure and subsurface‐initiated contact fatigue failures. To address this issue, a fatigue‐wear coupling model of an aviation gear pair was developed based on the elastic‐plastic finite element method. The tooth profile surface roughness was considered, and its evolution during repeated meshing was simulated using the Archard wear formula. The fatigue damage accumulation of material points on and underneath the contact surface was captured using the Brown‐Miller‐Morrow multiaxial fatigue criterion. The elastic‐plastic constitutive behavior of damaged material points was updated by incorporating the damage variable. Variations in the wear depth and fatigue damage around the pitch point are described, and the effect of surface roughness on the fatigue life is addressed. The results reveal that whether fatigue failure occurs initially on the surface or sub‐surface depends on the level of surface roughness. Mild wear on the asperity level alleviates the local stress concentration and leads to a longer surface fatigue life compared with the result without wear. Keywords: gear contact fatigue; tooth wear; surface roughness; damage accumulation
1 Introduction Gears are extensively utilized in numerous machines such as helicopters, ships, wind turbines, and vehicles. Particularly in the aviation, gears are important components that influence the reliability of helicopters, aero‐engines, vertical‐flight vehicles, and other aviation equipments [1]. There is a demand for improved performance, reduced weight, and increased temperature resistance in these aviation applications. Although there are many innovative manufacturing techniques, including surface superfinishing and shot peening that increase the life and reliability of these gears
[2], aviation gears can fail or lead to disastrous accidents due to fatigue failures [3]. Gear contact fatigue life is one of the main factors determining the time between overhauls (TBO) of aviation transmissions. The contact fatigue problems of aviation gears are an important bottleneck in the industry. Addressing them requires methods to pr
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