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Frontiers of Mechanical Engineering >> 2020, Volume 15, Issue 1 doi: 10.1007/s11465-019-0556-8

Contact fatigue life prediction of a bevel gear under spectrum loading

. State Key Laboratory of Mechanical Transmissions, Chongqing University, Chongqing 400044, China.. National Key Laboratory of Vehicular Transmission, Beijing Institute of Technology, Beijing 100081, China.. Propulsion Development Department, Chongqing Changan New Energy Vehicles Technology, Chongqing 401133, China

Accepted: 2019-12-09 Available online:2019-12-09

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Rolling contact fatigue (RCF) issues, such as pitting, might occur on bevel gears because load fluctuation induces considerable subsurface stress amplitudes. Such issues can dramatically affect the service life of associated machines. An accurate geometry model of a hypoid gear utilized in the main reducer of a heavy-duty vehicle is developed in this study with the commercial gear design software MASTA. Multiaxial stress–strain states are simulated with the finite element method, and the RCF life is predicted using the Brown–Miller–Morrow fatigue criterion. The patterns of fatigue life on the tooth surface are simulated under various loading levels, and the RCF curve is numerically generated. Moreover, a typical torque–time history on the driven axle is described, followed by the construction of program load spectrum with the rain flow method and the Goodman mean stress equation. The effects of various fatigue damage accumulation rules on fatigue life are compared and discussed in detail. Predicted results reveal that the Miner linear rule provides the most optimistic result among the three selected rules, and the Manson bilinear rule produces the most conservative result.

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