Crack nucleation and propagation modeling for lubricated spur gear contacts of rough surfaces

In this study, a rolling contact fatigue model for lubricated gear contacts of rough surfaces is proposed, considering both crack nucleation and propagation stages. A boundary element approach is implemented to describe surface roughness topography effect on near surface stress concentration, with surface tractions yielded from mixed EHL analysis. A fatigue criterion is employed to find crack nucleation position and life. Assuming mode II crack opening mechanism, stress intensity factor range is determined and used to arrive crack propagation life. Through comparisons to experiments, model capability is demonstrated. Simulation results show important roughness effect on crack propagation as well as crack nucleation.