Bevel gear performance improvement and service life prediction based on endurance testing

The objective of this project is to evaluate and enhance standardized gear design methods by comparing them against the actual performance of large-sized bevel gears. We conduct comprehensive endurance testing on gear sets that utilize advanced design and manufacturing techniques. Key areas of interest include:

• The impact of case hardening on the fatigue performance of the gears.
• Variations in failure modes under different design and operational conditions.
• The influence of different materials on the endurance performance of the gears.
• A fundamental understanding of fatigue-induced failure modes in large-sized bevel gears.

Standardized gear dimensioning methods are the primary process used in the gear manufacturing industry. However, discrepancies between theoretical loading conditions and actual usage highlight the need for improvements in these calculation methods. These differences become more pronounced with larger bevel gears. Given the high cost of producing such systems, it is crucial that the design is accurate from the outset, as the typical manufacturing volumes of such systems are quite low.

The goal of this project is to understand fatigue-related failure modes in large-sized bevel gears. By gaining deeper insights into fatigue-based failures, such as pitting and tooth interior fatigue, we aim to develop new calculation methods and evaluate existing methods to accurately predict the ultimate failures of gear sets.

DSII - Doctoral School of Industry Innovation