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<p>The present study investigates the influence of initial tooth face pitting defects on the wear characteristics of helical gears in shaft system components. This study utilizes ANSYS simulation software to conduct a transient contact stress simulation on a gear system afflicted with tooth face pitting defects. The objective of this analysis is to elucidate the influence of various pitting defect locations on the tooth face contact stress and strain distribution. The findings indicate that when the defect is positioned at a distance of approximately 15&#xa0;mm from the leftmost edge of the gear graduated circle, the gear contact stress attains a maximum value of 711.45&#xa0;MPa. Therefore, a gear wear characterization test platform was designed and constructed to further investigate the wear mechanism of helical gears under the initial defect. The vibration amplitude, abrasive particle concentration, abrasive particle characteristics, and gear micro-wear morphology of the gears were comprehensively characterized by using the four dimensions of vibration acceleration sensor, particle counter, iron spectrometer, and scanning electron microscope. The experimental results demonstrate that the introduction of initial pitting defects leads to abnormal frequencies and amplitudes in the gear system, thereby altering the energy distribution of the vibration signals. Furthermore, oil sample analysis corroborates the alterations in abrasive particle concentration and morphology. Furthermore, the initial defects had a substantial impact on the fatigue wear and material spalling of the gears, resulting in uneven gear wear, deterioration of the micro-morphology, and the appearance of a considerable number of furrows and material spalling. Consequently, these factors increased the risk of gear fracture. This study offers a foundational theoretical framework for the identification of faults, estimation of remaining life, and development of intelligent maintenance programs for gear systems.</p>

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Wear Characteristics of Helical Gears with Initial Tooth Surface Pitting Defects of Shafting

  • 期刊论文

  • 发表日期：

    2026年2月23日

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  • Angang Yan,
  • Jikang Wang,
  • Xingju Yao,
  • Jun Xia,
  • Zhigiang Zhang,
  • Xiao Guo,
  • Wei Yuan

摘要

The present study investigates the influence of initial tooth face pitting defects on the wear characteristics of helical gears in shaft system components. This study utilizes ANSYS simulation software to conduct a transient contact stress simulation on a gear system afflicted with tooth face pitting defects. The objective of this analysis is to elucidate the influence of various pitting defect locations on the tooth face contact stress and strain distribution. The findings indicate that when the defect is positioned at a distance of approximately 15 mm from the leftmost edge of the gear graduated circle, the gear contact stress attains a maximum value of 711.45 MPa. Therefore, a gear wear characterization test platform was designed and constructed to further investigate the wear mechanism of helical gears under the initial defect. The vibration amplitude, abrasive particle concentration, abrasive particle characteristics, and gear micro-wear morphology of the gears were comprehensively characterized by using the four dimensions of vibration acceleration sensor, particle counter, iron spectrometer, and scanning electron microscope. The experimental results demonstrate that the introduction of initial pitting defects leads to abnormal frequencies and amplitudes in the gear system, thereby altering the energy distribution of the vibration signals. Furthermore, oil sample analysis corroborates the alterations in abrasive particle concentration and morphology. Furthermore, the initial defects had a substantial impact on the fatigue wear and material spalling of the gears, resulting in uneven gear wear, deterioration of the micro-morphology, and the appearance of a considerable number of furrows and material spalling. Consequently, these factors increased the risk of gear fracture. This study offers a foundational theoretical framework for the identification of faults, estimation of remaining life, and development of intelligent maintenance programs for gear systems.