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<p>A systematic failure analysis was conducted on the planet gears of the wheel-end reducer of a tracked vehicle. The analysis was primarily conducted from two perspectives: metallographic analysis and system dynamics modeling. The metallographic analysis included macroscopic fracture analysis, microscopic fracture analysis, microstructural observation, hardness test, and XRD approach. Macroscopic fracture analysis revealed that the fracture at the root of the planet gear teeth was caused by excessive root axial stress due to overload. Scanning electron microscopy indicated irregularly sized ductile dimples in the fracture zone, which are typical characteristics of ductile fracture. Considering the meshing stiffness and transmission error, it is found that the planetary gear is in a single-tooth meshing state for a long time and has a serious bias load. Finite element analysis was used to evaluate the stress distribution of the planet gear during service. The stress of the planet gear was 658.0 MPa, which exceeded the permissible stress value of the material, 593.4 MPa. The system dynamics modeling results were completely consistent with the material analysis results, thereby supporting the hypothesis of the cause of the failure. Failure is caused by the combined effects of dynamic stress concentration dominated by single-tooth meshing and systematic misalignment induced by transmission error.</p>

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Study on Plastic Overload Fracture of Planet Gears in Wheel-side Reducer Based on Dynamic Simulation and Fracture Analysis

  • 期刊论文

  • 发表日期：

    2025年12月4日

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  • Xiuju Du,
  • Qingzhen Zhang,
  • Yanhua Zhang,
  • Shaoru Zhang,
  • Yonglin Zhang,
  • Qinglin Fan,
  • Wenhui Liu

摘要

A systematic failure analysis was conducted on the planet gears of the wheel-end reducer of a tracked vehicle. The analysis was primarily conducted from two perspectives: metallographic analysis and system dynamics modeling. The metallographic analysis included macroscopic fracture analysis, microscopic fracture analysis, microstructural observation, hardness test, and XRD approach. Macroscopic fracture analysis revealed that the fracture at the root of the planet gear teeth was caused by excessive root axial stress due to overload. Scanning electron microscopy indicated irregularly sized ductile dimples in the fracture zone, which are typical characteristics of ductile fracture. Considering the meshing stiffness and transmission error, it is found that the planetary gear is in a single-tooth meshing state for a long time and has a serious bias load. Finite element analysis was used to evaluate the stress distribution of the planet gear during service. The stress of the planet gear was 658.0 MPa, which exceeded the permissible stress value of the material, 593.4 MPa. The system dynamics modeling results were completely consistent with the material analysis results, thereby supporting the hypothesis of the cause of the failure. Failure is caused by the combined effects of dynamic stress concentration dominated by single-tooth meshing and systematic misalignment induced by transmission error.