THE ANNALS OF UNIVERSITY “DUNĂREA DE JOS “ OF GALAŢI 89

FASCICLE VIII, 2005, ISSN 1221-4590

TRIBOLOGY

PITTING MODEL IN THE CONTACT AREA OF SPUR GEARS

Sorin CĂNĂNĂU
University POLITEHNICA of Bucharest, Romania
scananau@meca.omtr.pub.ro

ABSTRACT
The paper presents a new model for the initiation and growth of the pits in the
contact area of spur gears. The main criterion to split the process into two phases
(initiation and growth of cracks) is the number of cycles.
The process of crack initiation is based on the theory of initiation along
inclusions (grains) interfaces. The second phase, the sort crack growth is studied
using finite element method for simulation of the crack propagation. Each phase is
characterized by geometric and analytical model.
The comparison with numerical results shows a good agreement.

KEYWORDS: gear, pitting, contact problem, finite element method.

1. INTRODUCTION In this process the initial surface or subsurface

In the power transmission tribology the gear
systems design is difficult. The main problem
concerns the correct prediction of possible gear failure
and is bounded by several requirements as high loads,
high speed, minimal weight etc.
The principal mode of failure of gears systems is
the surface pitting of gear teeth flanks. Pitting occurs
within small cracks are initiated on the tooth surface
or just below the surface [1].
The main cause of the initiation consists in metal-
to-metal contact of asperities or defects due to low
lubricant film thickness. The cracks may start at
inclusion in the gear flank (or foreign particle
contamination of lubricant), which act as stress
concentrators and propagate due to normal and
tangential loads [2]
Fig. 1. Pitting phenomenon at gear tooth flank surface.
breaking initial cracks grow under contact dynamic
loads.
At one point in time the crack becomes large
enough for unstable grow to occur and a small part of
surface material layer is breaking away.
In the gear case the pitting process is amplified by
the fact that the sliding and rolling velocities act in
opposite directions. This process is dependent of
material and operating conditions. In any case the
complete fatigue process of micro-pit formation
consists of several stages:
 the crack initiation;
 the crack growth;
 the destruction of the surface layer at high rate;
 the destruction of the surface layer at low rate.
2. MODEL OF MICRO-PIT
DESTRUCTION
Consequent with the physical model the process
and the stages presented in Introduction, the calculus
model will be divided into two parts: the first model is
associated with fatigue crack initiation under load and
the second model is associated with fatigue crack
development under contact loading.
The main criterion for separation of these two
models is present also in classical standardized
procedures DIN 3990 and AGMA 218.01 for
prediction of service life in gears operation and
consists in defining two numbers of stress cycles [2]:
 Ni – the number required for the appearance
of the initial crack in the material;
 Nj – the number required for growth of the
crack in the material.
90 THE ANNALS OF UNIVERSITY “DUNĂREA DE JOS “ OF GALAŢI
FASCICLE VIII, 2005, ISSN 1221-4590
TRIBOLOGY
Concerning the first model we assume the
hypotheses of the fatigue crack initiation along
inclusion interfaces in a single crystal grain and this
could be, in the real case, one hard inclusion in the
form carbides in high strength steel alloys.
The theoretical model presented in figure 2
represents the model with an inclusion [2]. The
contact projection of a spherical inclusion is characte-
rized by the diameter din and the shear modulus Gin .
Projection
Gin G will be a function of plastic strain amplitude [5]. The
of inclusion
d in
l
Contact
slip zone L Ni = k
Fig.2 Inclusion model in the surface slip zone
This inclusion is residing in a slip zone, an
ellipse with semi-major axis L and semi-minor axis l.
The shear modulus of the material, G, is the
shear modulus of the gear material [2].
The model of crack initiation due to a grain
presence assumes that the dislocation stress
(consequent tangential load) τd is equal to [ 3]:
G ⋅ Gin
τd = γ1
G + Gin (1)
where γ1 is the plastic strain in the grain due to one
cycle loading with applied shearing stress τmax:
( l + L ) τ max − τ f
γ1 = ⋅ (2)
l G
In this equation τf is the frictional stress due to
frictional forces activated in the meshing process.
In this case the strain energy W stored due to the
pressure of inclusion is equal to:
π [ d in ( l + L )( ∆τ − 2τ f )] 2
W= (3)
8l 2 ( G + Gin )
According the real pitting phenomenon deve-
lopment the strain energy increment ∆W, correspond-
ding to the each loading cycle is obtained substituting
τmax with the loading interval ∆τ. This interval is:
∆τ = τ max − τ min (4)
We split the friction stress τf into two equal
components corresponding to the material resistance
at dislocation motion for sliding velocities in the
opposite directions [4]. The result is presented in
equation (5):
8( G + Gin ) τ max − τ f
∆W = ⋅ (5)
d ⋅G ( ∆τ − 2τ f )2
If the energy increment is a function of
materials, grain dimension and contact stress ∆τ, we
can express the number of stress cycles required for
crack initiation Ni as a function of the same
parameters:
N i = 2πdγ 1 / ∆W (6)
in consequence:
8( G + Gin ) τ max − τ f
Ni = ⋅ (7)
d ⋅G ( ∆τ − 2τ f )2
We consider that the process of grains'
dislocation is irreversible. Connected with this
hypothesis we can say that the number of cycles Ni
constant k will take into account the irreversibility
factor and this factor takes values:
k = 10 −1..10 −4 (8)
In this case, the number of cycles Ni is expressed
in equation (9):
8( G + Gin ) τ max − τ f
⋅ (9)
d in ⋅ G ( ∆τ − 2τ f )2
This number is an estimate of required number
of loading cycle grain with inclusion, positioned in the
area of maximum contact stress ∆τ [6].
Concerning the crack development we can
assume that the cracks are defined as being short
because their length are small and are associated with
the process of surface pitting.
The theory of short crack growth is used to
model the crack development associated with pitting
phenomenon. We can use the theory of short crack
growth only considering the characteristic dimension
of material microstructure (the grain dimension) of the
same seize with the length of the crack development.
But the dimension of the diameter of the hole is
from units to thousands of grain characteristic dimen-
sion. That means the cracks extend from a dimension
of a small grain to a much larger scale. The model of
crack growth must taken into account the transfer of
the phenomenon from the grain of the initial crack to
tens (or thousands) neighboring grains. This implies
the discontinuity of this process. We have also to
consider the decrease of crack growth rate as the crack
approaches, grain by grain, to a grain-boundary.
We need to consider that the contact model will
be imported from one grain to another but the energy
will decrease due to slip barriers. But at the moment
when the stress concentration is significant and able to
initiate displacements the crack growth increases.
The crack growth rate da/dN is assumed to be
proportional to the stress intensity range, ∆K [2]:
( da / dN ) = C ⋅ ∆K m (10)
where C and m are empirical parameters.
Using the geometrical model presented in the
figure3 and based on several studies realized using
finite element method and some experimental data [4]
we can express a relation between stress intensity
range ∆K and plastic displacements ∆u:
2 ∆K ( c2 − a2 )
∆u = ⋅ (11)
G πa
 THE ANNALS OF UNIVERSITY “DUNĂREA DE JOS “ OF GALAŢI 91
FASCICLE VIII, 2005, ISSN 1221-4590
TRIBOLOGY

where c is crack length associated with plastic zone The material of the gear is considered a hardened
and a is crack length. steel alloy with yield stress σlim = 1300MPa and the
gear (as pinion) is subject of a torque load applied
T=200Nm.
The finite element analysis was conducted to
asses with large approximation grains-polycrystalline
distribution at the surface, considering a contact zone.
The analysis is a 2D-plain strain analysis, with 4-
nodes quadrilateral elements. The number of total
elements is 2176.
The present model taken into account the load
applied corresponding to single pair teeth engagement
and the maximum value for the load applied in inner
point of this load distribution.
Fig. 3. Model of short crack development.
In accordance with our hypotheses we consider in
the same time a frictional load at the contact surface
Consequent, the crack growth rate equation is:
as tangent vectors of profile geometry. The values of
( da / dN ) = C1 ⋅ ∆u n (12)
these forces are determinate using Amontons-
where C1 and n are empirical parameters. Coulomb friction laws and a coefficient of friction
The number of cycles Nj can be obtain with µ=0.06 – an average value considered for lubricated
integration of eq. (12): gears.
a The real geometry of contact pinion-gear was
da
Nj = ∫ C1 ⋅ ( ∆u )n
for j=1..z (13) replace with a classical geometry of equivalent cylin-
a j −1 ders. The curvature radii for pinion in the inner point
where z is total number of grains observed in crack of single teeth engagement is R1=11.240 mm. With
growth process. the model shown in figure 4 we are able to use Hertz
Concerning development of the crack in each theory for determination of the resulting maximum
grain we assume that is a critical length of a that equivalent von Misses stress in the material and, very
confirms the irreversibility of development of that important, the localization of this maximum.
crack. In consequence, there is a critical number ncr
=(acr/c) where ncr can be defined, using elements from
[7]:
∆K π K
n cr = cos[ ⋅ (1− ⋅ n cr ) (14)
2σ lim c ⋅ n cr ∆K
where K is the limit, the threshold of stress intensity
range ∆K.
Fig. 4 Model for determination of von Misses stress
3. NUMERICAL ANALYSIS in the susceptible zone of crack initiation.

Numerical analysis has the aim to establish the The result shown in figure 5 indicate that the
relationship ∆K=f(a) utilizing a virtual crack crack could be initiated along inclusion interface in
extension method. In the first step we will study the the point of maximum equivalent stress σmax=785
possibility of the crack initiation as consequence of MPa at a depth of H=0.117 mm
normal and tangential load applied. This first step of analysis is accomplished with
The model used for numerical determination of calculus of number of cycles Ni in accordance with eq.
pitting resistance of a spur gear is given in Table 1. (9).
Table 1
Pinion Gear
Module, mm 5
Standard pressure angle 200
Number of teeth 15 21
Addendum coefficient +0.571 0
modification
Tip circle diameter , mm 93.210 117.5
Center distance, mm 90
Face width, mm 18 16
Contact ratio 1.246
 92 THE ANNALS OF UNIVERSITY “DUNĂREA DE JOS “ OF GALAŢI
FASCICLE VIII, 2005, ISSN 1221-4590
TRIBOLOGY

Fig. 5. The state of stress in the contact area.

In this equation applied stress amplitude ∆τ is step by step, through each fracture element, as the For
the maximum equivalent stress σmax. Concerning the this step we used special fracture finite elements. With
frictional stress we can consider τf =(20…25) MPa, this type of element, we can calculate the stress
according to [7], as material resistance to the motion intensity factor. Near the initial point of crack the
of dislocations. The diameter din of the inclusion stress intensity factor is at low level but,crack
(grain) we assume to be as the same size as the finite propagates through material to the surface, the stress
element size in the contact area discretization. For the intensity factor increase. In this analysis each fracture
geometric model presented and for the chosen scale, element is considered as a grain of flank material. The
we can assume the average value din = 100µm. In result is shown in table2.
figure 6 is shown the results for different values of
characteristic dimension of grain, din from 10-3 to 1 Table2
mm. It is obvious that the pitting resistance is very low Number Integration Stress Number of
level (Ni =103…104 cycles) for a grain dimension of limits, intensity, stress
din=(0.1.. 1) mm but the average dimension considered fracture aj-1,aj ∆K, cycles,
for is correct because the pitting resistance for din element [Nmm-3/2] Nj
grain dimension din=(0.001..0.01) mm is Ni =107...108 1 0.01,0.023 320 5.7e7
cycles, result in accordance with experiment from [4]. 2 0.023,0.055 410 6.3e6
Also, we introduce, in the same analysis, the notation
3 0.055,0.09 517 1.1e6
λ= Gin/G to reflect the influence of the inclusion
4 0.09,0.135 611 8.2e5
material.
5 0.135,0.15 730 4.0e5
6 0.15,0.18 851 1.02e5
7 0.18,0.22 940 7.14e4
8
10 8 0.22,0.27 1015 5.11e4
λ=1
Number of cycles N i

8,10E+07
8x10
7 9 0.27,0.33 1120 3.45e4
λ=2 10 0.33,0.41 1230 2.25e4
7
6,10E+07
6x10 11 0.41,0.49 1310 1.60e4
λ=3
7
4,10E+07
4x10 λ=4
4. CONCLUSIONS
7
2,10E+07
2x10 λ=5
The stress intensity factor and the crack length
6
1,00E+06
10 were determined using a finite element method. The
0,001
0.001 0,010
0.01 0,100
0.1 1,000
1 number of cycles which is characteristic for pitting
resistance of spur gears was calculated using an
Grain inclusion size d in [ mm]
analytical model and the results of FEM analysis.

Fig. 6. Number of cycles required for fatigue crack REFERENCES

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In the second step of this analysis we develop on
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The local discretization around the initial crack is
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Fig. 7. Crack propagation study.