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Article

Early Crack Propagation in Single Tooth Bending Fatigue: Combination of Finite Element Analysis and Critical-Planes Fatigue Criteria

1
Faculty of Science and Technology, Free University of Bolzano/Bozen, Piazza Università 1, 39100 Bolzano, Italy
2
Department of Mechanical Engineering, Politecnico di Milano, via La Masa 1, 20157 Milano, Italy
*
Authors to whom correspondence should be addressed.
Academic Editors: Filippo Berto, Ricardo Branco and Shengchuan Wu
Metals 2021, 11(11), 1871; https://doi.org/10.3390/met11111871
Received: 28 October 2021 / Revised: 17 November 2021 / Accepted: 17 November 2021 / Published: 21 November 2021
(This article belongs to the Special Issue Computational Methods for Fatigue and Fracture)
Mechanical components, such as gears, are usually subjected to variable loads that induce multiaxial non-proportional stress states, which in turn can lead to failure due to fatigue. However, the material properties are usually available in the forms of bending or shear fatigue limits. Multiaxial fatigue criteria can be used to bridge the gap between the available data and the actual loading conditions. However, different criteria could lead to different results. The main goal of this paper is to evaluate the accuracy of different criteria applied to real mechanical components. With respect to this, five different criteria based on the critical plane concept (i.e., Findley, Matake, McDiarmid, Papadopoulos, and Susmel) have been investigated. These criteria were selected because they not only assess the level of damage, but also predict the direction of crack propagation just after nucleation. Therefore, measurements (crack position and direction) on different fractured gear samples tested via Single Tooth Bending Fatigue (STBF) tests on two gear geometries were used as reference. The STBF configuration was numerically simulated via Finite Elements (FE) analyses. The results of FE were elaborated based on the above-mentioned criteria. The numerical results were compared with the experimental ones. The result of the comparison showed that all the fatigue criteria agree in identifying the most critical point. The Findley and Papadopulus criteria proved to be the most accurate in estimating the level of damage. The Susmel criterion turns out to be the most conservative one. With respect to the identification of the direction of early propagation of the crack, the Findley criterion revealed the most appropriate. View Full-Text
Keywords: gears; Single Tooth Bending Fatigue; STBF; Finite Element Model; FEM; material characterization; multiaxial fatigue; critical plane gears; Single Tooth Bending Fatigue; STBF; Finite Element Model; FEM; material characterization; multiaxial fatigue; critical plane
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MDPI and ACS Style

Concli, F.; Maccioni, L.; Fraccaroli, L.; Bonaiti, L. Early Crack Propagation in Single Tooth Bending Fatigue: Combination of Finite Element Analysis and Critical-Planes Fatigue Criteria. Metals 2021, 11, 1871. https://doi.org/10.3390/met11111871

AMA Style

Concli F, Maccioni L, Fraccaroli L, Bonaiti L. Early Crack Propagation in Single Tooth Bending Fatigue: Combination of Finite Element Analysis and Critical-Planes Fatigue Criteria. Metals. 2021; 11(11):1871. https://doi.org/10.3390/met11111871

Chicago/Turabian Style

Concli, Franco, Lorenzo Maccioni, Lorenzo Fraccaroli, and Luca Bonaiti. 2021. "Early Crack Propagation in Single Tooth Bending Fatigue: Combination of Finite Element Analysis and Critical-Planes Fatigue Criteria" Metals 11, no. 11: 1871. https://doi.org/10.3390/met11111871

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