“Analysis of crack propagation during tooth interior fatigue

fracture”
M. MackAldener, M. Olsson, 2002

Presented by: Conrad de Kock

11 October 2017 1
 Summary
 Context
 Objectives
 Key Results
 Conclusions

 Significance
 To the research field
 To my work

 Reflections
 What I learnt
 Critique of approach
 Challenges in understanding

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 TIFF (tooth interior fatigue fracture) - failure
mode that is initiated as a fatigue crack in the
interior of the tooth of a gear
 Occurs in case hardened idler gears (gears with
teeth loaded on both its gear flanks during each
revolution)

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 Fatigue failure divided into three phases – initiation,
propagation and rapid failure
 Crack propagation phase is analysed by FEA and
fractographic examination
 Fractography – establish
and examine the origin of
a crack on a macro scale

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 Validity of LEFM – cracks larger than 0.2mm
 Crack initiation – mid height, below case core boundary
 Two questions – is crack propagation fast, and does it slow down
once it reaches the case layer?
 3D mesh with 3D crack dimensions
 Results from FE based on real load situations
 Simplifications
 Stress intensity factor results –
 Propagation in the interior of the tooth
 Propagation in the case layer

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 Paris’ law of crack growth increment
 Constants C and m determined by fatigue test,
DCT-specimens
 Least squares used to determine C and m

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 Range in stress intensity factors at different
crack lengths is of interest
 Mixed mode load – growth of fatigue cracks
complicated
 Effective SIF range
 Propagation in the interior – small crack to
large crack in 10 cycles
 Propagation into the case layer – propagated
then seizes

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 Observed deflection was always directed
towards the root and the deflection angle
varied between 35° and 55°
 FE analysis was carried through for a 2.2 mm
long and 7.7 mm wide crack which had its
right crack tip in the case layer at the position
for the observed crack and its left crack tip
located at the centre line of the tooth.

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 Silent assumptions
 There exists an inherent crack length
 Paris’ law used in mixed mode loading
 Crack closure effects neglected
 Paris’ law valid for internal crack free of oxidation

 Results
 A TIFF crack is initiated in the interior of the tooth and will propagate
into the case layer where it stops
 The main crack propagation will take place into the core, creating a
plateau
 The crack propagation into the core is of the order of 10 cycles
 The crack deflection towards the root can be understood if the
redistribution of the tooth force due to the reduced tooth stiffness of a
cracked tooth is considered
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 Significance of the paper to the research field
 Successfully correlates numerous fracture mechanics and fatigue theories into
an applicable model for a real world application
 Presents a feasible, functional relationship between loading conditions, material
properties and gear tooth crack propagation

 Significance of the paper to my work

 Automotive gears aren’t different from industrial gears
 Interesting topic relevant to industrial gearbox industry

 What did I learn?

 K_II mode very applicable!
 Case hardening – double purpose

 What did I not like about their approach?

 Crack deflection not explored as in-depth as FEA and experimental approach

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