Experimental investigation of crack growth behaviors and mechanical properties degradation during gear bending fatigue

Tooth bending fatigue remains as a fundamental bottleneck restricting the safety and reliability of modern high-performance gear. In this study, a serial of bending fatigue tests on case carburized and shot peening treated gears is conducted. The fatigue crack propagation behaviors during bending fatigue test were analyzed. The alternations of macroscopic mechanical properties and microstructure features of gear samples subjected to bending fatigue are experimentally examined and analyzed in detail. It is found that the measured tooth root crack trajectories basically conform to the dangerous section of the tooth root determined by the 30° tangent method with a slight variation of about 1°. The phenomena of residual stress relaxation in gear bending fatigue is observed with the maximum residual compressive stress decreasing from −698 MPa of intact state to −572 MPa of failure state. Furthermore, the content of retained austenite of tooth root surface decreases by about 3.8 % after the gear bending fatigue failure, and the grain size of the tooth root core region illustrates a certain tendency of coarsening.