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Research Article | Open Access

Simulation of the fatigue-wear coupling mechanism of an aviation gear

Boyu ZHANG1, Huaiju LIU1( ), Caichao ZHU1, Yibo GE2
State Key Laboratory of Mechancial Transmissions, Chongqing University, Chongqing 400044, China
Shanghai Peentech Equipment Tech. Co. Ltd., Shanghai 201800, China
Show Author Information

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 fatiguetooth wearsurface roughnessdamage accumulation

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Friction
Volume 9 Issue 6,
December 2021
Pages 1616-1634
DOI: 10.1007/s40544-020-0447-3
Cite this article:
ZHANG B, LIU H, ZHU C, et al. Simulation of the fatigue-wear coupling mechanism of an aviation gear. Friction, 2021, 9(6): 1616-1634. https://doi.org/10.1007/s40544-020-0447-3

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Received: 31 March 2020
Revised: 09 July 2020
Accepted: 21 August 2020
Published: 01 December 2020
© The author(s) 2020

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