Rim Thickness Effects on Gear Crack Propagation Life |
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Authors: | David G Lewicki Roberto Ballarini |
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Affiliation: | (1) Vehicle Propulsion Directorate, U.S. Army Research Laboratory, NASA Lewis Research Center, Cleveland, OH, 44135;(2) Department of Civil Engineering and of Mechanical & Aerospace Engineering, Case Western Reserve University, Cleveland, OH, 44106-7201 |
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Abstract: | Analytical and experimental studies were performed to investigate the effect of gear rim thickness on crack propagation life.
The FRANC (FRacture ANalysis Code) computer program was used to simulate crack propagation. The FRANC program used principles
of linear elastic fracture mechanics, finite element modeling, and a unique re-meshing scheme to determine crack tip stress
distributions, estimate stress intensity factors, and model crack propagation. Various fatigue crack growth models were used
to estimate crack propagation life based on the calculated stress intensity factors. Experimental tests were performed in
a gear fatigue rig to validate predicted crack propagation results. Test gears were installed with special crack propagation
gages in the tooth fillet region to measure bending fatigue crack growth. Good correlation between predicted and measured
crack growth was achieved when the fatigue crack closure concept was introduced into the analysis. As the gear rim thickness
decreased, the compressive cyclic stress in the gear tooth fillet region increased. The retarded crack growth and increased
the number of crack propagation cycles to failure.
This revised version was published online in August 2006 with corrections to the Cover Date. |
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Keywords: | Rims crack propagation crack growth gears fracture mechanics finite element modeling stress intensity factors |
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