Simulation of pitting formation in gearing

Abstract eng:
In the presented article is presented a numerical simulation approach of pitting arise phenomena on the gear teeth. The basic assumption of the presented approach was that pitting (pits on the contact surfaces) is a result of fatigue crack propagation under (rolling) contact loading conditions. The solution approach consisted of numerical simulations of fatigue cracks growth in the FEM framework. Fatigue crack growth simulations are based on evaluation of the so called Paris law in conjunction with FEA of crack tip loading conditions and fracture criteria evaluation. Penetration of the fluid lubricant into fatigue (pitting) cracks is simulated using special cavity finite elements, which allow to introduce so called lubricant closure inside crack. A simplified distribution of residual stresses in the surface layers of teeth is included as well. The simulations were carried out under the commercial code ABAQUS CAE FEM programme which allows to develop in-house codes using the Python scripting language. Mentioned programme codes are the basis of all FEA including the simulation of the contact loading conditions and the incremental crack growth.

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