This study proposes an approach for the acceleration of the experimental gear rolling contact fatigue (RCF) crack formation. By increasing the rotational velocity of a gear pair, the RCF experimental time period is reduced. However, the film thickness is increased to improve the fatigue performance, to counteract which it is proposed to raise the lubricant temperature to reduce the film thickness. A physics-based gear contact fatigue model is used to quantify and offset the effects of the rotational velocity and the lubricant temperature on the crack nucleation.

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