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<p>Tooth root fracture is one of the common types of failure in spur gears. In this study, a&#xa0;simulation procedure has been proposed to evaluate tooth root fracture in spur gears. The study estimates the total fatigue life of spur gears modeled from AISI 4140 hardened steel, including crack initiation and propagation. The strain-life approach was used for fatigue analysis of crack initiation, while the Separating Morphing and Adaptive Remeshing Technology (SMART) was used for crack propagation. The effect of different gear design parameters such as pressure angle, tooth width, profile shift, and crack initiation length on tooth root fracture was evaluated by modeling different geometric variations. Through extensive simulations carried out in Ansys software, it was found that the highest crack propagation occurred in the 25°&#xa0;pressure angle variation. In contrast, the lowest crack propagation was observed in the negative profile shift variation. Increasing the pressure angle and the positive profile shift increases the fatigue life of spur gears. Additionally, increasing the tooth width significantly increases fatigue life.</p>

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Simulation model for tooth root crack growth in spur gears based on geometric design properties

  • 期刊论文

  • 发表日期：

    2025年1月20日

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  • Ahmet Can Yildiz,
  • Tezcan Sekercioglu

摘要

Tooth root fracture is one of the common types of failure in spur gears. In this study, a simulation procedure has been proposed to evaluate tooth root fracture in spur gears. The study estimates the total fatigue life of spur gears modeled from AISI 4140 hardened steel, including crack initiation and propagation. The strain-life approach was used for fatigue analysis of crack initiation, while the Separating Morphing and Adaptive Remeshing Technology (SMART) was used for crack propagation. The effect of different gear design parameters such as pressure angle, tooth width, profile shift, and crack initiation length on tooth root fracture was evaluated by modeling different geometric variations. Through extensive simulations carried out in Ansys software, it was found that the highest crack propagation occurred in the 25° pressure angle variation. In contrast, the lowest crack propagation was observed in the negative profile shift variation. Increasing the pressure angle and the positive profile shift increases the fatigue life of spur gears. Additionally, increasing the tooth width significantly increases fatigue life.