Robust gear designs consider not only crack initiation, but crack propagation trajectories for a fail-safe design. In actual gear operation, the magnitude as well as the position of the force changes as the gear rotates through the mesh. A study to determine the effect of moving gear tooth load on crack propagation predictions was performed. Two-dimensional analysis of an involute spur gear and three-dimensional analysis of a spiral-bevel pinion gear using the finite element method and boundary element method were studied and compared to experiments. A modified theory for predicting gear crack propagation paths based on the criteria of Erdogan and Sih  was investigated. Crack simulation based on calculated stress intensity factors and mixed mode crack angle prediction techniques using a simple static analysis in which the tooth load was located at the highest point of single tooth contact was validated. For three-dimensional analysis, however, the analysis was valid only as long as the crack did not approach the contact region on the tooth.
Consideration of Moving Tooth Load in Gear Crack Propagation Predictions
Contributed by the Power Transmission & Gearing Committee for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received May 2000; revised Oct. 2000. Associate Editor: J. Gao.
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Lewicki , D. G., Handschuh , R. F., Spievak , L. E., Wawrzynek , P. A., and Ingraffea , A. R. (October 1, 2000). "Consideration of Moving Tooth Load in Gear Crack Propagation Predictions ." ASME. J. Mech. Des. March 2001; 123(1): 118–124. https://doi.org/10.1115/1.1338118
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