Finite element analysis of contact fatigue and bending fatigue of a theoretical assembling straight bevel gear pair

The aim of this work is to propose a 3D FE model of a theoretical assembling straight bevel gear pair to analyze the contact fatigue on the tooth surface and the bending fatigue in the tooth root. Based on the cumulative fatigue criterion and the stress-life equation, the key meshing states of the gear pair were investigated for the contact fatigue and the bending fatigue. Then, the reliability of the proposed model was proved by comparing the calculation result with the simulation result. Further study was performed to analyze the variation of the contact fatigue stress and the bending fatigue stress under different loads. Furthermore, the roles of the driving pinion and the driven gear pair were evaluated in the fatigue life of the straight bevel gear pair and the main fatigue failure mode was determined for the significant gear. The results show that the fatigue failure of the driving pinion is the main fatigue failure for the straight bevel gear pair and the bending fatigue failure is the main fatigue failure for the driving pinion.

Rotary bending fatigue behavior of A356 –T6 aluminum alloys by vacuum pressurizing casting

Vacuum pressurizing casting technique, providing better mould filling and inter-dendritic feeding, can reduce the porosity greatly in cast aluminum alloys, and improve the fatigue properties. The rotary bending fatigue properties of A356-T6 alloys prepared by vacuum pressurizing casting were investigated. The S-N curve and limit strength 90 MPa under fatigue life of 107 cycles were obtained. The analyses on the fatigue fractography and microstructure of specimens showed that the fatigue fracture mainly occurs at the positions with casting defects in the subsurface, especially at porosities regions, which attributed to the crack propagation during the fatigue fracture process. Using the empirical crack propagation law of Pairs-Erdogon, the quantitative relationship among the initial crack size, fatigue life and applied stress was established. The fatigue life decreases with an increase in initial crack size. Two constants in the Pairs-Erdogon equation of aluminum alloy A356-T6 were calculated using the experimental data.

An Analytical Method to Detect the Coupling Damage Relationship of Concrete Subjected to Bending Fatigue and Temperature Actions

Based on the assumptions validated by the experiments,an analytical method to detect the coupling actions of bending fatigue and temperature on concrete was proposed.To this purpose,a coefficient denoted by f D （T）with the strain distributions caused by these two actions was defined.In terms of the known parameters and the fitted functions of strain,the explicit expression for f D （T）which develops in the way same as the law of temperature change in the body of specimens was obtained.Our experimental results indicate that the weigh fraction of temperature stress decreases in the coupling damage field with the fading temperature gradient,and consequently disclose the mutual influence between these two types of actions in the loading history.

Experimental investigation of the relation between the surface integrity and bending fatigue strength of carburized gears

Bending fatigue is an essential parameter that needs to be considered in the improvement process of the power density and reliability of gear drives. Quantitative relations among the manufacturing parameters, surface integrities, and fatigue performance are not clear, which seriously limits the effectiveness of an anti-fatigue design. For this work, tooth-bending fatigue tests of carburized gears with different surface integrities were performed using a pulsator. The effects of the manufacturing parameters and surface integrities on the gear fatigue, such as surface hardness and residual stress, were investigated. The experimental results revealed that due to the improvement of surface integrities after shot peening, the nominal bending stress number(fatigue limit) increased by 6.3%–31.1%, with an amplitude range of 39–143 MPa. A supervised learning algorithm of a random forest was implemented to determine the contribution of the surface hardness and surface residual stress to the nominal stress number. An empirical formula was proposed to predict the nominal stress number considering the surface integrities. The prediction error was less than 7.53%, as verified by several gear-bending fatigue tests. This provided theoretical support for the modern, anti-fatigue design of the gears.

Bending fatigue behavior of thin Zr_(61)Ti_(2)Cu_(25)Al_(12)bulk metallic glass beams for compliant mechanisms application

In this work,bending fatigue behavior of thinner Zr_(61)Ti_(2)Cu_(25)Al_(12)(ZT1)BMG beams with thicknesses of 500μm and 100μm were investigated with three-point bending(3PB),to evaluate the reliability and safety of this potentially material used in compliant mechanisms under cyclic bending load.Fatigue endurance limits(FELs)of ZT1 beams with thicknesses of 500μm and 100μm were determined to be 470 MPa,and~0.3 of its tensile strength.Fatigue life and FEL of ZT1 beams in bending are substantially independent of the beam thickness,in the scale from 500μm down to 100μm.Fatigue cracks of all ZT1 beams initiated at the extrinsic microvoids,either indirectly derived from surface scratches during mechanical polishing or originated from as-cast process.However,fatigue crack propagation behavior is highly related to the magnitude of cyclic stress level.By interrupted fatigue tests,larger proportion about 60-70%of fatigue life was spent on crack propagation under high stress level,while crack initiation occupied larger proportion about 80-85%under low stress level.The medium stress level of about 590 MPa almost shared the crack-initiation life and crack-propagation life.In addition,there are two crack deflection mechanisms during cracks steady propagation stage.One mechanism is crack deflection along the interacted shear bands ahead of crack-tip,the other one is crack"jump"from one shear band to another shear band at a certain angle.These two mechanisms alternate dominate the crack propagation process,generating typical staircase-like crack propagation trajectory.Fatigue endurance limits of ZT1 beams in the form of either stress amplitude or strain amplitude are superior to traditional candidate materials in the field of compliant mechanisms,showing that the better reliability and larger deflection deformation can be achieved for flexible members made by ZT1 BMG even under cyclic loading.

Metal magnetic memory field characterization at early fatigue damage based on modified Jiles-Atherton model

In order to propel the development of metal magnetic memory （MMM） technique in fatigue damage detection, the Jiles-Atherton model （J-A model） was modified to describe MMM mechanism in elastic stress stage. A series of rotating bending fatigue experiments were conducted to study the stress-magnetization relationship and verify the correctness of modified J-A model. In MMM detection, the magnetization of material irreversibly approaches to the local equilibrium state Mo instead of global equilibrium state M^n under cyclic stress, and the M0-a curves are loops around the Mar,-a curve. The modified J-A model is constructed by replacing M~ in J-A model with M0, and it can describe the magnetomechanical effect well at low external magnetic field. In the rotating bending fatigue experiments, the MMM field distribution in normal direction around cylinder specimen is similar to the stress distribution, and the calculation result of model coincides with experiment result after some necessary modifications. The MMM field variation with time at a certain point in fatigue process is divided into three stages with the variation of stable stress-stain hysteresis loop, and the calculation results of model can explain not only the three stages of MMM field changes, but also the different change laws when the applied magnetic field and initial magnetic field are different. The MMM field distribution in normal direction along specimen axis reflects stress concentration effect at artificial defect, and the magnetic signal fluctuates around the defect at late fatigue stage. The calculation results coincide with the initial MMM principle and can explain signal fluctuates around the defect. The modified J-A model can explain experiment results well, and it is fit for MMM field characterization.

PROPAGATION OF SHORT FATIGUE CRACKS IN STEEL 16Mn

Small bar speeimens of steel 16Mn with blind-holes were fatigued under constant amplitude Ioadings on a rotathing bending fatigue machie.Short crack propagation emanating from the blind-holes was obtained.Based on the experimental results,an expression of average propa- gation rate of short cracks was proposed.Statistical behavior of short crack propagation was discussed and the evoluation of sutrface sizes of short cracks with fatigue cycle number was al- so given.

Test study on the fatigue performance of HSS for steel wheels

High-strength steel is currently one of the main material choices for creating lightw eight automobiles. To realize lighter wheels that can comply with harsh fatigue requirements,sufficient know ledge of the relevant material fatigue properties is required. Fatigue tests were conducted on Baosteel＇s 600 M Pa level dual-phase steel DP600,which is a typical high-strength hot-rolled steel for steel wheel,and on 550 M Pa level HR60. Whler（ S-N） fatigue curves were obtained for both steels,and the measured stress fatigue limits were 414 and 329 M Pa for the HR60 and the DP600,respectively.

Structural effects of three-dimensional angle-interlock woven composite undergoing bending cyclic loading

This paper reports the structural effects of three-dimensional(3-D)angle-interlock woven composite(3DAWC)undergoing three-point bending cyclic loading from experimental and finite element analysis(FEA)approaches.In experiment,the fatigue tests were conducted to measure the bending deflection and to observe the damage morphologies.By the FEA approach,a micro-structural unit-cell model of the 3DAWC was established at the yarn level to simulate the fatigue damage.The stress degradation at the loading condition of constant deformation amplitude was calculated to show the degradation of mechanical properties.In addition,the stress distribution,fatigue damage evolution and critical damage regions were also obtained to qualitatively reveal the structural effects and damage mechanisms of the 3DAWC subjected to three-point bending cyclic loading.

Performance of steel bridge deck pavement structure with ultra high performance concrete based on resin bonding

This research investigated a pavement system on steel bridge decks that use epoxy resin(EP)bonded ultra-high performance concrete(UHPC).Through FEM analysis and static and dynamic bending fatigue tests of the composite structure,the influences of the interface of the pavement layer,reinforcement,and different paving materials on the structural performance were compared and analyzed.The results show that the resin bonded UHPC pavement structure can reduce the weld strain in the steel plate by about 32%and the relative deflection between ribs by about 52%under standard axial load conditions compared to traditional pavements.The EP bonding layer can nearly double the drawing strength of the pavement interface from 1.3 MPa,and improve the bending resistance of the UHPC structure on steel bridge decks by about 50%;the bending resistance of reinforced UHPC structures is twice that of unreinforced UHPC structure,and the dynamic deflection of the UHPC pavement structure increases exponentially with increasing fatigue load.The fatigue life is about 1.2×10^(7) cycles under a fixed force of 9 kN and a dynamic deflection of 0.35 mm,which meets the requirements for fatigue performance of pavements on steel bridge decks under traffic conditions of large flow and heavy load.