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100 Results Found

  • Article
  • Open Access
10 Citations
2,573 Views
15 Pages

Digital Twin of a Gear Root Crack Prognosis

  • Omri Matania,
  • Eric Bechhoefer and
  • Jacob Bortman

17 December 2023

Digital twins play a significant role in Industry 4.0, offering the potential to revolutionize machinery maintenance. In this paper, we introduce a new digital twin designed to address the open problem of predicting gear root crack propagation. This...

  • Article
  • Open Access
21 Citations
3,884 Views
20 Pages

25 November 2020

The time-varying mesh stiffness (TVMS) is the crucial parameter of the dynamic model of the gear system. Accurate calculation of TVMS is essential for effective fault diagnosis of the gear system. A mesh stiffness improved method considering both the...

  • Article
  • Open Access
2 Citations
1,751 Views
24 Pages

15 December 2024

The motor gear system (MGS) is recognized for its potential in enhancing transmission efficiency and optimizing space utilization. However, the system is subjected to challenges, notably the occurrence of abnormal vibrations. These issues stem from t...

  • Article
  • Open Access
13 Citations
4,184 Views
26 Pages

Gear Crack Detection Based on Vibration Analysis Techniques and Statistical Process Control Charts (SPCC)

  • Rasheed Majeed Jorani,
  • Maroua Haddar,
  • Fakher Chaari and
  • Mohamed Haddar

20 February 2023

Vibration condition monitoring is a non-devastating technique that can be performed to detect tooth cracks propagating in gear systems. This paper proposes to apply a new methodology using time-domain analysis, frequency-domain analysis, and statisti...

  • Article
  • Open Access
18 Citations
3,330 Views
18 Pages

Effects of Tooth Surface Crack Propagation on Meshing Stiffness and Vibration Characteristic of Spur Gear System

  • Lan-tao Yang,
  • Yi-min Shao,
  • Wei-wei Jiang,
  • Lu-ke Zhang,
  • Li-ming Wang and
  • Jin Xu

23 February 2021

Tooth surface cracks are considered as the early stage of the development of tooth surface spalling failure. Understanding the excitation mechanism of surface cracks has a great significance in the early diagnosis of spalling faults. However, there a...

  • Article
  • Open Access
11 Citations
2,581 Views
24 Pages

26 December 2022

This paper established the system dynamics model for two kinds of tooth cracks of different depths of the sun gear and inner gear ring to study the influence mechanism of crack failure on the tooth root strain of the planetary gear transmission syste...

  • Article
  • Open Access
22 Citations
6,021 Views
20 Pages

9 April 2021

Planetary gearbox systems are critical mechanical components in heavy machinery such as wind turbines. They may suffer from various failure modes, due to the harsh working environment. Dynamic modeling is a useful method to support early fault detect...

  • Article
  • Open Access
8 Citations
2,721 Views
31 Pages

6 December 2022

Dynamic modeling and analysis are generally regarded as effective tools to investigate the vibration characteristics and fault mechanisms of planetary gear systems with a tooth crack fault. In actual gearboxes, the tooth crack is always a three-dimen...

  • Article
  • Open Access
1 Citations
2,347 Views
29 Pages

18 April 2024

Detecting gear rim fatigue cracks using vibration signal analysis is often a challenging task, which typically requires a series of signal processing steps to detect and enhance fault features. This task becomes even harder in helicopter planetary ge...

  • Article
  • Open Access
6 Citations
1,567 Views
20 Pages

6 August 2024

To solve the problem that the existing planetary gear train fault diagnosis methods have, namely their low diagnostic accuracy under low signal-to-noise ratio (SNR), a fault diagnosis method based on a double channel-deep residual shrinkage network (...

  • Article
  • Open Access
791 Views
18 Pages

14 June 2025

Helical idler gear transmission systems can adapt to high-speed, heavy-load working environments and are thus widely used in aerospace, shipbuilding, and other heavy industry sectors. Root crack is one of the common fault types. Prior studies general...

  • Article
  • Open Access
1,758 Views
20 Pages

2 October 2024

This paper discusses the possible early crack detectability performances of low contact ratio (LCR) and high contact ratio (HCR) spur gears. CAD models of the LCR and HCR gears are created using the rack cutter type tool. Static bending stress analys...

  • Article
  • Open Access
9 Citations
2,351 Views
12 Pages

31 May 2023

Thin-rim gears are widely used in industrial fields such as aerospace and electric vehicles due to the advantage of light weight. Yet, the root crack fracture failure of thin-rim gears significantly limits their application and further affects the re...

  • Article
  • Open Access
675 Views
23 Pages

In this paper, the time-varying mesh stiffness (TVMS) of a gear is meticulously derived using the potential energy method (PEM) and an analytical expression for it is obtained. Subsequently, calculations are performed to determine the effects of crac...

  • Article
  • Open Access
2 Citations
2,888 Views
23 Pages

Influence of Coexistence of Pitting and Cracking Faults on a Two-Stage Spur Gear System

  • Kemajou Herbert Yakeu Happi,
  • Bernard Xavier Tchomeni Kouejou and
  • Alfayo Anyika Alugongo

8 February 2023

This work considers forced vibrations in a rotating structure consisting of a two-stage spur gear system with coexisting defects, specifically pitting and cracking. Numerical simulations and experimental analysis in various scenarios of the system in...

  • Article
  • Open Access
13 Citations
5,229 Views
15 Pages

Evaluation of Fatigue Crack Propagation of Gears Considering Uncertainties in Loading and Material Properties

  • Haileyesus B. Endeshaw,
  • Stephen Ekwaro-Osire,
  • Fisseha M. Alemayehu and
  • João Paulo Dias

29 November 2017

Failure prediction of wind turbine gearboxes (WTGs) is especially important since the maintenance of these components is not only costly but also causes the longest downtime. One of the most common causes of the premature fault of WTGs is attributed...

  • Article
  • Open Access
9 Citations
1,983 Views
16 Pages

Effect of Initial Crack Position on Crack Propagation Behaviors of Heavy-Duty Transmission Gear

  • Yingtao Zhang,
  • Zirong Tang,
  • Lijuan Zhao,
  • Benxiang Gong,
  • Gang Wang and
  • Zhichao Li

31 August 2023

The tooth bending fatigue fracture is caused by the alternating loads for the heavy-duty transmission gears. The crack initiation and propagation are the two major parts in the failure process. The crack propagation behavior is mainly affected by ini...

  • Article
  • Open Access
7 Citations
2,958 Views
13 Pages

30 April 2021

In view of the lack of image enhancement processing in the traditional methods in image preprocessing, which leads to a long detection time for internal cracks in the image and poor visual effects, an intelligent detection method for internal cracks...

  • Article
  • Open Access
248 Views
25 Pages

25 November 2025

As a key component of pure electric vehicles, the reducer plays a vital role in power transmission and overall drive system performance. This study investigates the nonlinear dynamic characteristics of helical gears with tooth root crack faults in hi...

  • Article
  • Open Access
5 Citations
2,873 Views
16 Pages

6 August 2022

To study the dynamic characteristics of spur gears with crack faults, it is essential to establish the meshing stiffness model accurately. In this paper, the time-varying meshing stiffness (TVMS) model and load-sharing ratio (LSR) model of spur gears...

  • Article
  • Open Access
14 Citations
3,643 Views
25 Pages

Dynamic Simulation of Cracked Spiral Bevel Gear Pair Considering Assembly Errors

  • Hongzheng Han,
  • Hui Ma,
  • Haixu Wang,
  • Jiazan Zhu,
  • Zhanwei Li and
  • Zimeng Liu

13 October 2022

The tooth root crack fault is a common fault type of the spiral bevel gear pair (SBGP). Affected by the strong bearing capacity, the early crack fault of the SBGP cannot be found in time. In this study, a finite element (FE) model of the SBGP is esta...

  • Article
  • Open Access
1 Citations
1,361 Views
25 Pages

A planetary gear fault generates periodic speed fluctuations, which significantly influence its vibration signal. It is a necessity to explore the vibration modulation features of gear faults to provide an effective indicator for fault detection. The...

  • Article
  • Open Access
2 Citations
1,489 Views
24 Pages

Dynamic Characteristics of Gear System Under Compound Fault of Tooth Root Crack and Bearing Outer Ring

  • Yu Bai,
  • Hong Jiang,
  • Xiangfeng Zhang,
  • Zhen Lei,
  • Wenhan Huang,
  • Zhijie Zhu and
  • Chaochao Cui

12 December 2024

Research on single faults like tooth root cracks and bearing outer ring failures is well-established. However, existing studies often replace the actual crack propagation path with a simplified linear crack model, neglecting the variation in stress i...

  • Article
  • Open Access
250 Views
25 Pages

1 January 2026

This paper presents a hybrid knowledge-based expert system (KBES) designed to predict crack incubation and fatigue life in gear design, serving as both a research tool and an educational resource. While crack growth and initiation are well understood...

  • Article
  • Open Access
25 Citations
4,848 Views
14 Pages

Fault Diagnosis of Crack on Gearbox Using Vibration-Based Approaches

  • Sufyan A. Mohammed,
  • Nouby M. Ghazaly and
  • Jamil Abdo

19 February 2022

This study experimentally investigates vibration-based approaches for fault diagnosis of automotive gearboxes. The primary objective is to identify methods that can detect gear-tooth cracks, a common fault in gearboxes. Vibrational signals were super...

  • Article
  • Open Access
1,136 Views
20 Pages

Experimental Study on Bending Fatigue Performance of ADI Gears Under Different Applied Load Levels

  • Lijun Wang,
  • Hui Wei,
  • Hsinshen Ho,
  • Bo Hu,
  • Yangyang Li and
  • Dongfei Wang

21 August 2025

As austempered ductile iron (ADI) is a key gear material for meeting the lightweight and cost-effective demands of new energy vehicles, its bending fatigue performance has a direct impact on vehicle transmission efficiency. In the present work, QTD 8...

  • Article
  • Open Access
18 Citations
9,320 Views
17 Pages

2 December 2015

The unexpected failures of structural materials in very high cycle fatigue (VHCF) regime have been a critical issue in modern engineering design. In this study, the VHCF property of a Cr-Ni-W gear steel was experimentally investigated under axial loa...

  • Article
  • Open Access
7 Citations
2,323 Views
14 Pages

8 September 2022

Carburized Cr-Ni steel is widely used in the manufacture of components in many fields due to excellent performance, of which the service life has been a concern. In order to investigate the high-cycle-fatigue and very-high-cycle-fatigue properties of...

  • Article
  • Open Access
3 Citations
1,689 Views
16 Pages

27 November 2024

This study focuses on the planetary gear reducer and employs ANSYS 13.0 software to perform thermo-mechanical coupled simulations for the laser cladding repair process, aiming to address gear failure caused by cracks. The optimal theoretical repair p...

  • Article
  • Open Access
768 Views
14 Pages

Failure Analysis of Gear on Rail Transit

  • An-Xia Pan,
  • Chao Wen,
  • Haoyu Wang,
  • Ping Tao,
  • Xuedong Liu,
  • Yi Gong and
  • Zhen-Guo Yang

18 October 2025

The gear transmission system is a safety-critical component in rail transit, typically designed for a service life exceeding 20 years. Failure analysis of such systems remains a key focus for railway engineers. This study systematically investigates...

  • Article
  • Open Access
9 Citations
3,800 Views
25 Pages

9 November 2022

The crack fault has an important influence on the vibration characteristics of the transmission system. This paper is devoted to analyzing fault mechanism and dynamic characteristics of transmission with gear crack, which provides the basis for crack...

  • Article
  • Open Access
5 Citations
2,946 Views
14 Pages

3 October 2019

Keeping a coating–substrate system undamaged during heavy-load elastohydrodynamic lubrication (EHL) conditions is challenging. To overcome this problem, an EHL model with a coated gear pair was built. Firstly, based on the full-system finite el...

  • Article
  • Open Access
14 Citations
4,355 Views
21 Pages

11 April 2019

The gear is one of the important parts of a rotary gearbox. Once catastrophic gear failure occurs, it will cause a great threat to production and life safety. The crack is an important failure factor causing changes in time-varying stiffness and vibr...

  • Article
  • Open Access
17 Citations
3,716 Views
29 Pages

Analysis of Time-Varying Mesh Stiffness and Dynamic Response of Gear Transmission System with Pitting and Cracking Coupling Faults

  • Yiyi Kong,
  • Hong Jiang,
  • Ning Dong,
  • Jun Shang,
  • Pengfei Yu,
  • Jun Li,
  • Manhua Yu and
  • Lan Chen

21 April 2023

The gear transmission system is an important part of the mechanical system, so it is essential to judge its running state accurately. To solve the difficult problem of identifying the components of coupling faults, this paper derives the calculation...

  • Article
  • Open Access
16 Citations
3,522 Views
30 Pages

23 March 2023

Gears are fundamental components used to transmit power and motion in modern industry. Their health condition monitoring is crucial to ensure reliable operations, prevent unscheduled shutdowns, and minimize human casualties. From this standpoint, the...

  • Article
  • Open Access
600 Views
32 Pages

9 October 2025

Planetary gearbox serves as a key transmission component in planetary ball screw actuator systems. Under the action of alternating loads, the stress concentration locations of the planet carrier in actuators with planetary gear trains are prone to fa...

  • Article
  • Open Access
4 Citations
3,113 Views
35 Pages

A Hybrid Finite Element Method–Analytical Model for Classifying the Effects of Cracks on Gear Train Systems Using Artificial Neural Networks

  • Ronant de Paula Monteiro,
  • Amanda Lucatto Marra,
  • Renato Vidoni,
  • Claudio Garcia and
  • Franco Concli

4 August 2022

Rotating machinery is fundamental in industry, gearboxes especially. However, failures may occur in their transmission components due to regular usage over long periods of time, even when operations are not intense. To avoid such failures, Structural...

  • Article
  • Open Access
1,530 Views
21 Pages

11 January 2024

Before a new type of engine is introduced into civil aviation, it must comply with various safety regulations. These regulations include the analysis of secondary damage caused by the re-ingestion of a tooth fragment. The purpose is to prevent crack...

  • Article
  • Open Access
6 Citations
3,131 Views
41 Pages

As the core component of the wind turbine generation gearbox, the gear-rotor-bearing transmission system typically operates in harsh environments, inevitably leading to the occurrence of composite faults in the system, which exacerbates system vibrat...

  • Article
  • Open Access
4 Citations
5,065 Views
27 Pages

3 November 2022

To address flexural fractures and predict fatigue life, an ordinary state-based peridynamic (PD) fatigue model is proposed for the initiation and propagation of flexural fractures. The key to this model is to replace the traditional partial different...

  • Article
  • Open Access
6 Citations
2,287 Views
29 Pages

Compound Fault Characteristic Analysis for Fault Diagnosis of a Planetary Gear Train

  • Yulin Ren,
  • Guoyan Li,
  • Xiong Li,
  • Jingbin Zhang,
  • Runjun Liu and
  • Sifan Shi

31 January 2024

The carrier eccentricity error and gear compound faults are most likely to occur simultaneously in an actual planetary gear train (PGT). Various faults and errors are coupled with each other to generate a complex dynamic response, which makes the dia...

  • Article
  • Open Access
5 Citations
3,677 Views
21 Pages

Wear of AlCrN and CrAlSiN Coatings Applied to Nonstandard Involute Gears

  • Pavol Švec,
  • Miroslav Bošanský,
  • Ernest Gondár,
  • František Toth and
  • Roman Protasov

Wear of nonstandard involute gears with two types of coatings, AlCrN and CrAlSiN, was studied. The coatings were applied by cathodic arc deposition. The gears were tested using a Niemann tester at a graduated load up to the 12th load stage and were c...

  • Article
  • Open Access
10 Citations
2,512 Views
19 Pages

Wind Turbine Gearbox Diagnosis Based on Stator Current

  • Idris Issaadi,
  • Kamel Eddine Hemsas and
  • Abdenour Soualhi

10 July 2023

Early detection of faults in wind energy systems can reduce downtime, operating, and maintenance costs while increasing productivity. This paper proposes a method based on the analysis of generator stator current signals to detect faults in a wind tu...

  • Article
  • Open Access
5 Citations
2,825 Views
17 Pages

A New Fast Calculating Method for Meshing Stiffness of Faulty Gears Based on Loaded Tooth Contact Analysis

  • Zhe Liu,
  • Haiwei Wang,
  • Fengxia Lu,
  • Cheng Wang,
  • Jiachi Zhang and
  • Mingjian Qin

3 July 2023

Gear transmission systems are widely used in various fields. The occurrence of gear cracks, tooth pitting, and other faults will lead to the dynamic characteristics deterioration of the transmission system. In order to calculate the meshing stiffness...

  • Article
  • Open Access
3 Citations
1,930 Views
21 Pages

25 November 2024

To improve the contact fatigue life of gears, we studied the effect of adding a certain proportion of the Al element to a 20MnCr5 steel FZG spur gear under different heat treatment processes, characterizing the retained austenite and residual compres...

  • Article
  • Open Access
14 Citations
11,900 Views
17 Pages

A Bevel Gear Quality Inspection System Based on Multi-Camera Vision Technology

  • Ruiling Liu,
  • Dexing Zhong,
  • Hongqiang Lyu and
  • Jiuqiang Han

25 August 2016

Surface defect detection and dimension measurement of automotive bevel gears by manual inspection are costly, inefficient, low speed and low accuracy. In order to solve these problems, a synthetic bevel gear quality inspection system based on multi-c...

  • Feature Paper
  • Article
  • Open Access
27 Citations
3,776 Views
17 Pages

21 November 2021

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...

  • Article
  • Open Access
1,012 Views
11 Pages

12 August 2025

This article investigates the formation of solidification cracks in steel forgings used for bearing rings in gear reducers of robotic arms. The forging and heat treatment processes, conducted under consistent technological conditions, revealed the oc...

  • Article
  • Open Access
12 Citations
5,023 Views
18 Pages

14 September 2021

Advanced aircraft gearboxes operate under high mechanical loads. Currently, aircraft gears are manufactured from chromium–nickel–molybdenum steel grades such as AISI 9310 or Pyrowear 53. The major causes of gear failure are wear and fatigue cracking....

  • Article
  • Open Access
3,152 Views
15 Pages

5 January 2025

The wind turbine gearbox, used as a multiplier, is one of the main components directly related to a wind turbine’s efficiency and lifespan. Therefore, strict control of the gearbox and its manufacturing processes and even minor improvements in...

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