New research device for the investigation of gear damage type tooth flank fracture in analogy experiment

 

Starting Situation

Experimental investigations on gear load carrying capacity are nowadays carried out in the research environment with the aid of the two-shaft stress test rig. This test bench concept is basically suitable for the investigation of any type of damage, whereby the type of damage occurring depends on the design of the test toothing. Individual damage mechanisms and basic investigations will continue to be carried out with the aid of analogy test benches. Such an analogy test bench does not exist for the investigation of the tooth flank fracture bearing capacity. Tooth flank fractures occur in particular on large gears. However, the use of the two-shaft stress test bench is subject to technical and economic restrictions with regard to the size of the gear to be examined. Further development and statistical validation of calculation approaches for tooth flank fracture bearing capacity using the existing running test is therefore not feasible.

Research Objective

The objective of the proposed research project is the detailing, implementation and testing of an economic analogy experiment for the investigation of tooth flank fracture damage on large gearing. In order to achieve the objective, a design review is carried out to elaborate the detailed design of the analogy test bench. The transferability of the damage mechanism to the analogy test is checked by simulative analyses of the stress in the analogy test for different gearing geometries. Based on this, the test bench components are procured, manufactured and assembled. A comprehensive validation of the test bench concept serves to prove that tooth flank fractures can be investigated separately from other damage mechanisms with the test bench concept used.