Prediction of micropitting damage in gear teeth contacts considering the concurrent effects of surface fatigue and mild wear
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Published version
Author(s)
Morales-Espejel, GE
Rycerz, P
Kadiric, A
Type
Journal Article
Abstract
The present paper studies the occurrence of micropitting damage in gear teeth contacts. An existing general micropitting model, which accounts for mixed lubrication conditions, stress history, and fatigue damage accumulation, is adapted here to deal with transient contact conditions that exist during meshing of gear teeth. The model considers the concurrent effects of surface fatigue and mild wear on the evolution of tooth surface roughness and therefore captures the complexities of damage accumulation on tooth flanks in a more realistic manner than hitherto possible. Applicability of the model to gear contact conditions is first confirmed by comparing its predictions to relevant experiments carried out on a triple-disc contact fatigue rig. Application of the model to a pair of meshing spur gears shows that under low specific oil film thickness conditions, the continuous competition between surface fatigue and mild wear determines the overall level as well as the distribution of micropitting damage along the tooth flanks. The outcome of this competition in terms of the final damage level is dependent on contact sliding speed, pressure and specific film thickness. In general, with no surface wear, micropitting damage increases with decreasing film thickness as may be expected, but when some wear is present micropitting damage may reduce as film thickness is lowered to the point where wear takes over and removes the asperity peaks and hence reduces asperity interactions. Similarly, when wear is negligible, increased sliding can increase the level of micropitting by increasing the number of asperity stress cycles, but when wear is present, an increase in sliding may lead to a reduction in micropitting due to faster removal of asperity peaks. The results suggest that an ideal situation in terms of surface damage prevention is that in which some mild wear at the start of gear pair operation adequately wears-in the tooth surfaces, thus reducing subsequent micropitting, followed by zero or negligible wear for the rest of the gear pair life. The complexities of the interaction between the contact conditions, wear and surface fatigue, as evident in the present results, mean that a full treatment of gear micropitting requires a numerical model along the lines of that applied here, and that use of overly simplified criteria may lead to misleading predictions.
Date Issued
2018-03-15
Date Acceptance
2017-11-21
Citation
Wear, 2018, 398-399 (1), pp.99-115
ISSN
0043-1648
Publisher
Elsevier
Start Page
99
End Page
115
Journal / Book Title
Wear
Volume
398-399
Issue
1
Copyright Statement
© 2017 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/BY-NC-ND/4.0/)
Sponsor
Commission of the European Communities
SKF (UK) Ltd
Identifier
https://www.sciencedirect.com/science/article/pii/S0043164817309535
Grant Number
PIAP-GA-2013-612306
n/a
Subjects
Science & Technology
Technology
Engineering, Mechanical
Materials Science, Multidisciplinary
Engineering
Materials Science
FRICTION
LUBRICATION
0910 Manufacturing Engineering
0912 Materials Engineering
0913 Mechanical Engineering
Mechanical Engineering & Transports
Publication Status
Published
OA Location
https://doi.org/10.1016/j.wear.2017.11.016
Date Publish Online
2017-11-24