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Procedia Structural Integrity 18 (2019) 406–412

25th International Conference on Fracture and Structural Integrity

25th International Conference on Fracture and Structural Integrity
Failure analysis of a crane gear shaft
Failure analysis of a crane gear shaft
Goran Vukelicaa, D. Pastorcicbb*, G. Vizentinaa
Goran Vukelic , D. Pastorcic *, G. Vizentin
a
University of Rijeka, Faculty of Maritime Studies, Marine Engineering Department, Studentska 2, 51000 Rijeka, Croatia
a
University of Rijeka, Faculty of Maritime Studies,
bUniversity of Zadar,Marine Engineering
Maritime Department,
Department, Studentska 2, 51000 Rijeka, Croatia
Zadar, Croatia
bUniversity of Zadar, Maritime Department, Zadar, Croatia

Abstract
Abstract
This research deals with a teeth failure of a gear shaft that served as a part of shipyard crane drive train. Almost all of the teeth of
This research
a spiral bevel deals withof
gear, part a teeth failure
a larger of fractured
shaft, a gear shaft that normal
during served as a part ofofshipyard
operation the crane.crane driveanalysis
Failure train. Almost
combinedall ofexperimental
the teeth of
aand
spiral bevel gear, part of a larger shaft, fractured during normal operation of the crane. Failure
numerical research. Visual inspection was employed to determine the fracture location and crack propagation paths. analysis combined experimental
and numerical
Microscopy, research.
optical Visual inspection
and scanning electron (SEM),was employed
was used to to inspect
determine the fracture
damaged surfaceslocation and crack
of the teeth, reveal propagation
possible flaws paths.
and
Microscopy,
fine opticalofand
microstructure thescanning
material.electron
Type of(SEM), wasfor
steel used used to inspect damaged
manufacturing surfaces of
was determined the on
based teeth, reveal composition
chemical possible flaws of and
the
fine microstructure
material obtained usingof theoptical
material. Type of
emission steel used for
spectrometer withmanufacturing
glow dischargewassource
determined
(GDS) based on chemical
sample composition
stimulation. of the
Further, tensile
material
specimens obtained using optical
were extracted from theemission spectrometer
shaft to test the strengthwith glow
of the discharge
steel. sourcehardness
Additionally, (GDS) testsample
was stimulation.
performed. All Further, tensile
experimental
specimens were extracted
research suggest it is a case from the shaft
of gear teethtospalling,
test the strength
probablyofcaused
the steel.
byAdditionally, hardness
excessive contact test was
stresses. performed.
To gain All experimental
better understanding of
research suggest
the failure it isa a3D
process, case of gear teeth
numerical modelspalling, probably
of the gear caused
shaft was byand
built excessive contact (FE)
finite element stresses. Toanalysis
stress gain better understanding
performed. of
Analysis
the failure
showed process,contact
excessive a 3D numerical
stresses atmodel of thecontact
the teeth gear shaft
area.was built and finite
Time-varying element
meshing (FE) stress
stiffness analysis
(TVMS), performed.
an important Analysis
gear health
showed
conditionexcessive
parameter, contact stresses at
is determined viathe
FEteeth contact
procedure forarea.
severalTime-varying
examples ofmeshing
healthy stiffness
to gradually(TVMS),
damaged an gear.
important gear results
Obtained health
condition
show howparameter, is determined
spall propagation via FE
influences TVMS procedure for several
and, thus, examples
affects gear of healthy
performance to gradually
leading damaged
to potential gear. Obtained results
failure.
show how spall propagation influences TVMS and, thus, affects gear performance leading to potential failure.
© 2019 The Authors. Published by Elsevier B.V.
© 2019 The Authors. Published by Elsevier B.V.
© 2019 The Authors.
Peer-review under Published by
responsibility of Elsevier
the Gruppo B.V.Italiano Frattura (IGF) ExCo.
Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo.
Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo.
Keywords:gear; bevel gear; crane gear shaft; failure analysis
Keywords:gear; bevel gear; crane gear shaft; failure analysis

* Corresponding author. Tel.: 0038598891042.

* Corresponding author. Tel.: 0038598891042.
E-mail address:dpastorci@unizd.hr
E-mail address:dpastorci@unizd.hr
2452-3216© 2019 The Authors. Published by Elsevier B.V.
2452-3216© 2019 The
Peer-review under Authors. Published
responsibility by Elsevier
of the Gruppo ItalianoB.V.
Frattura (IGF) ExCo.
Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo.

2452-3216  2019 The Authors. Published by Elsevier B.V.

Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo.
10.1016/j.prostr.2019.08.182
 Goran Vukelic et al. / Procedia Structural Integrity 18 (2019) 406–412 407
2 Vukelic, Pastorcic, Vizentin/ StructuralIntegrity Procedia 00 (2019) 000–000

1. Introduction

Gears are almost unavoidable components of every machine. Their application ranges from transmission systems
in automotive, plane and marine industry, to special applications in power generating and processing plants. Gears
design ranges from simple to sophisticated gear pairs and, along with their complexity, rises the need for thorough
understanding of acting stresses and, consequently, possible failures. It is especially important as the data show that
gear failures make up about 10% of all rotating machinery failures[1].
As for the gear failures, two common types of localized tooth defects are recognized [2]. One is the tooth fillet
crack and the other tooth surface spalling. As previous research shows, fillet cracks usually develop in the tooth fillet
region. They are caused by deficiencies in the gear tooth which result in stress concentration points that act as a root
of subsequent damage. On the other hand, gear tooth spalling tends to develop in the region near the pitch circle of the
tooth surface where the tooth pair is subjected to a higher mesh force. Gear tooth spallings are a product of extremely
high localized contact stresses that act as damage initiators.
There has been a considerable effort in researching the causes of gear failures and offering the propositions for
design improvements. Some of the recent work on gear failures includes investigation of a failed axle of a reduction
gearbox where, using experimental procedures, was concluded that at the initiation site during the case carburization
quenching cracks were formed [3]. Failure analysis of a helical gear used in a bus gearbox indicated that teeth of the
helical gear failed by fatigue with a fatigue crack initiation from destructive pitting and spalling region at one end of
tooth in the vicinity of the pitch line because of misalignment [4]. Experimental and numerical study of microstructural
degradation of a failed pinion gear at a cement plant has proven that the concentration of tensile residual stresses due
to untempered core at the tip aided the micropitting and micro-cracking due to the rolling contact surface fatigue was
responsible for the initiation of surface cracks and final failure of the gear [5].
Understanding the causes of gear damage and failures is important since it can contribute to the prevention of
catastrophic machinery failures. This paper deals with a teeth failure of a gear shaft that serves as a part of shipyard
crane drive train. Almost all of the teeth of a spiral bevel gear, part of a larger shaft, fractured during normal operation
of the crane. Failure analysis presented here combines experimental and numerical research giving insight how did the
damage propagated and influenced the performance of the gear pair.

2. Experimental procedures

2.1. Visual observations

A gear shaft that serves as a part of shipyard crane drive train failed with 15 of its 17 helical teeth damaged. It is a
spiral bevel gear, part of a larger shaft. Spiral bevel gears find their main application vehicle differentials, where the
direction of drive from the drive shaft must be turned 90 degrees to drive the wheels. Design that is characterized by
the helical teeth is capable of providing less vibration and noise than conventional gears with straight teeth. Spiral
bevel gears come in pairs and once damaged, they should both be changed. Geometry and dimensions of considered
spiral bevel pinion are shown in Fig. 1.

Fig. 1. Geometry and dimensions (in mm) of the considered pinion shaft.
408 Goran Vukelic et al. / Procedia Structural Integrity 18 (2019) 406–412
Author name / Structural Integrity Procedia 00 (2019) 000–000 3

The pinion shaft was a part of the first stage of the crane gearbox., with the engine power of 20 kW at 1200 rpm.
Total weight of the pinion shaft is 7.06 kg. Fig. 2 presents a close-up of the gear with damaged teeth. A damage pattern
can easily be detected with teeth gradually being brought to excessive contact and damage evolving over the gear.
Little or no corrosion occurred on the gear shaft.

Fig. 2. Fractured spiral bevel gear. Dashed line shows the evolution of damage contact.

Fig. 3 presents the teeth damage at the characteristic positions along each tooth, the start of excessive contact,
middle point of damage area and final point of damage area. Figures are taken at suitable magnification using Olympus
SZX10 stereo optical microscope.

a) b) c)

Fig. 3. Fractured spiral bevel gear with marked locations of performed optical micrographyat 12.5x magnification: a) location 1a showing
initiation section of damage area, b) location 1b showing middle section of damage area, c) location 1c showing end section of damage area.
 Goran Vukelic et al. / Procedia Structural Integrity 18 (2019) 406–412 409
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2.2. Material

Chemical composition of the gear material was determined using glow discharge spectrometer (GDS) LECO
GDS500A, Tab. 1.

Table 1. Chemical composition of the gear material (wt%).

C Mn Si P S Mo Ni Cr V Rest
0.25 0.18 0.24 0.024 0.021 0.35 2.2 1.00 0.06 95.725

Composition of tested material is adequate to the special alloy structural steel 28NiCrMoV8-5. The alloy structural
steels are widely used in automotive, plane and marine industry, guided missile, weapons, railway, bridges, pressure
vessels, machine tools, mechanical components with a bigger sectional size, etc.
It is a spring steel typically used in manufacturing of light and heavy vehicle leaf springs and coil springs, safety
valve springs, shock absorbers on heavy machinery, instrument springs, friction plates, etc. Comparing the
composition of the tested steel to standard EN 10250-3:2000, it can be noted that the percentage of nickel is just over
the standard range (1.8-2.1 %), while chromium is just at the minimum value (1-1.5 %).
As there was enough material, three standard tensile test specimens were machined out of shaft part and tensile test
performed to determine material yield strength of 473 MPa, tensile strength of 820 MPa and Young modulus of 188
GPa. All of the values are within standard range for steel 28NiCrMoV8-5.

2.3. SEM analysis

Fracture surfaces on the specimens cut from gears, Fig. 4, were examined using scanning electron microscope
(SEM) FEI Quanta 250 under suitable magnification. Spalling damage can be detected along the damage area.

a) b) c)

Fig. 4. SEM of fractured spiral bevel gearat locations corresponding to Fig. 3: a) location 1a, 50x magnification, b) location 1b, 31x
magnification, c) location 1c, 60x magnification.

3. Calculation

Finite element (FE) model of considered gear pair was built in order to perform a numerical analysis of the stress and
the contact pressure. Scanned dimensions of the gear pair were used to build 3D FE model of tetrahedron elements in
Ansys, with mesh refinement of teeth and contact surfaces. In order to verify FE model, first, a stress analysis,
according to DIN 3991[6], is performed. The gear ratio is 4, with pinion and gear number of teeth 17 and 68,
respectively. The gear pair was loaded with 700 Nm on the output. Maximum equivalent stress obtained numerically
410 Goran Vukelic et al. / Procedia Structural Integrity 18 (2019) 406–412
Author name / Structural Integrity Procedia 00 (2019) 000–000 5

is 495.26 MPa, Fig. 5. In accordance with DIN 3991, analytically calculated tooth root stress, σF, and permissible
tooth root stress, σFP, for the pinion are σF = 215,74 MPa and σFP = 481,63 MPa. The permissible value of contact
stress, σHP, and existing surface pressure, σPHP, are σHP = 574,96 MPa and σPHP = 1011,76 MPa , respectively. Maximum
surface pressure obtained numerically is 914,16 MPa, Fig 6.
Results differ by no more than 3% for the equivalent stress and 9% for the existing surface pressure giving confidence
in further use of FE model.

a) b)

Fig. 5. Spiral bevel gear pair: a) FE model with mesh, b) pinion equivalent stress

Fig. 6. Pinion surface contact pressure

Besides the FE model of undamaged gear pair, the 3D model of the damaged pinion flanks, as well as the model of
the damaged pinion teeth tip were also considered, Fig 7., in order to obtain time varying mesh stiffness (TVMS)[7],
Fig. 8., asan important parameter of the system condition.The quasi-static algorithm (QSA) is used for computing the
TVMS[9].
 Goran Vukelic et al. / Procedia Structural Integrity 18 (2019) 406–412 411
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a) b)

Fig. 7. Spiral bevel gear pair: a) pinion damaged flanks, b) pinion damaged tooth tip.

105
1.47
undamaged
flank damage
1.46 teeth tip damage

1.45

1.44

1.43

1.42

1.41

1.4
0 5 10 15 20 25
Pinion angular position (°)

Fig. 8. Time varying mesh stiffness (TVMS)

4. Discussion and conclusion

Visual examination of the failed spiral bevel gear damage evolving around gear teeth. This damage was probably
caused by the mismatch between the gear and the pinion designed axial lines causing unwanted contact between the
bodies. This contact resulted in raising the stress points along the gear teeth and excessive stress gradually worn out
the surface of the teeth. This tends to be the case of gear tooth spalling. Spallings are a product of extremely high
localized contact stresses that act as damage initiators and they tend to develop in the region near the pitch circle of
the tooth surface where the tooth pair is subjected to a higher mesh force.
As the analysis showed, gear was made of special alloy structural steel 28NiCrMoV8-5. It is a common choice for
manufacturing gears exposed to heavy duty tasks. This steel with somewhat elevated content of nickel and chromium.
Chromium at steels tends to increase tensile strength, hardness, toughness, resistance to wear and corrosion, while
nickel increases strength and hardness without sacrificing ductility and toughness. It can also increase resistance to
412 Goran Vukelic et al. / Procedia Structural Integrity 18 (2019) 406–412
Author name / Structural Integrity Procedia 00 (2019) 000–000 7

corrosion and scaling at elevated temperatures. Measured yield and maximum tensile strength are in line with expected
for steel 28NiCrMoV8-5.
Optical and scanning electron microscopy images revealed damage to the teeth surface. Damage evolving around
teeth can clearly be tracked, from the introduction point to the end of contact. The origin of the damage can be tracked
to the point where the sum of all applied and misapplied stresses intersect the net strength of the gear. Spalling
originated below the surface, near the case/core transition surface, leading to final failure of the gear shaft.
Comprehensive data of the research performed include adequate images of fractured surface at suitable magnification
with details of damage growth and advancement.
Numerical analysis indicated localized high contact stresses and TVMS reduction for damaged gear teeth. In order
to reduce the contact stress and the effects of high contact stress, material of pinion should be case hardened steel and
positive profile shift on the pinion should be performed in manufacturing.
Obtained results can be used in understanding the damage, wear and failure behavior of spiral bevel gears in heavy
duty gearboxes and further improvements of gear design, manufacturing, finishing and assembly could be made based
on this analysis.

Acknowledgements

This work has been supported by the University of Rijeka within the project uniri-technic-18-200 “Failure analysis
of materials in marine environment”.

References

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