Investigation of the initiation and propagation of cracks in the coated surface of spur gear: An application of irreversible cohesive zone model

¹ Division of Mechanical Engineering, School of Engineering, Manchester Metropolitan University, M1 5GD, UK
² Centre for Precision Manufacturing, Dept. of Design, Manufacture & Engineering Management, The University of Strathclyde, Glasgow G1 1XJ, UK
³ Surface Engineering, University of Birmingham, Birmingham B15 2TT, UK

^a Corresponding author: e-mail: j.feng@mmu.ac.uk

Abstract

Spur gears are the most common type of gears for industry, due to its simple structures and low costs of manufacture. Under the action of rolling contact fatigue, the main mode of the coated teeth failure is surface or subsurface originated micro-pitting, leading to the debonding of coating from substrate, fracture in the coating and even subsurface failure. Failure may originate from initiation of cracks, and its growth and propagation, however, basic failure mechanism is still not clear. In this paper, a comprehensive finite element modeling procedure including submodelling techniques and irreversible cohesive zone modelling techniques (CZM) is developed to investigate the failure mechanisms under the rolling contact fatigue loading. The details of the localized stresses distribution will be simulated using the submodelling technique. Irreversible CZM will be used to simulate the initiation and propagation of the cracks in the coated surface of the spur gears under the cyclic contact loading.