A SEMINAR REPORT ON

FATIGUE GAILURE OF HELICAL GEARS

BY
MR. JAMADAR IMRAN M. ROLL NO. -102090005

UNDER THE GUIDANCE OF Prof. RATHOD

DEPARTMENT OF MECHANICAL ENGINEERING 2010-11

Contents
1. 2. 3. 4. 5. Introduction
Case study Experimental procedure Results and discussion Conclusion

Introduction

Failure analysis of helical gear used in a bus gearbox History-Gear has been in use for 3 years Material-AISI 8620 Steel Evaluation methods-Visual inspection, photo documentation, chemical analysis, micro hardness measurement, metallographic examination

TYPES OF GEAR FAILURES

Fatigue Impact Fracture Wear Stress Rupture Surface contact fatigue- pitting, spalling

CAUSES

Poor design of gear set Misalignment of gears Overloads Subsurface defects in internal areas Use of incorrect materials and heat treatment

CASE STUDY

Bus with problem with its transmission gearbox Gearbox running hot with excessive vibrations Problem was with the fourth speed drive gear

General appearance of failed helical gear

Parameters Number of teeth helical gear Helix angle Module, normal (mm)

Value 36

150 4

Pitch circle diameter (mm)

Outer diameter (mm) Face width (mm)

150

158 42

Spectrum analysis and micro hardness measurement

Result revealed that material was AISI8620 carburized steel Core hardness =439HV Surface hardness=550Hv Case depth=0.63mm Microstructure consist of martensite and retained austenite

Microstructure

Visual inspection

No. of adjacent teeth failed due to fatigue A triangular piece of the teeth had broken off Crack initiation and bench marks can be seen by necked eyes Origin of crack was at the pitch line No corrosion media were found on fractured surface

Photograph of failed gear tooth

Pitting

Destructive pitting and spalling were also noted on loaded side of each tooth Destructive pitting appears as much larger pits than initial pitting In spalling pits are large in diameter and quite shallow Spalling is caused by excessively high contact stress

Photograph of Pitted gear teeth

SEM and EDX Examination

SEM inspection to identify cause of fatigue crack initiation and propagation River-like pattern could be seen in propagation zone EDX attached to fractured surface to determine gear chemistry To verify presence of any other associated components

Crack initiation and propagation

Conclusion

Composition, microstructure, hardness and case depth found satisfactory Fractographic features indicated that fatigue was the main failure cause Misalignment was observed which has caused failure Formation of destructive pitting and spalling at one end was due to load concentration at that area

THANK YOU!