Simulating Fatigue Crack Growth in Spiral Bevel Gears

Abstract The boundary element method and linear elastic fracture mechanics theories are used to predict three dimensional fatigue crack trajectories in a spiral bevel pinion under a moving load. It is found that the moving load produces a non-proportional load history in a gear’s tooth root. An approach that accounts for fatigue crack closure effects is developed to propagate the crack front under the non-proportional load. The predictions are compared to experimental results. The sensitivity of the predictions to variations in loading conditions and crack growth rate model parameters is explored. Critical areas that must be understood in greater detail prior to predicting more accurate crack trajectories and crack growth rates in three dimensions are identified.

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