Spur Gear Crack Propagation Path Analysis Using Finite Element Method

An effective gear design balances strength, durability, reliability, size, weight and cost. However unexpected gear failure may occur even with adequate gear tooth design. Failure of the engineering structures is caused by crack, which depends on the design and operating conditions and can be avoided by analyzing and understanding the manner it originates. To develop design guidelines to prevent failure modes considering gear tooth fracture, by studying the crack propagation path in a spur gear. Crack propagation paths are predicted for a variety of gear tooth geometry at various crack initiation location. The effects of gear tooth thickness, pitch radius, and tooth pressure angle are considered. Analysis is being carried out using FEM with the principles of linear elastic fracture mechanics and mixed mode fracture criteria. The stress intensity factors are the key parameters to estimate the characteristics of a crack. Design charts & Design guidelines or fracture mechanics will be formed considering the effects or gear geometry, applied load, crack size and material property.