Search Results (30)

This paper presents the results of a numerical study on the influence of the tooth root fillet manufacturing method on the bending strength of spur gears with straight teeth. A mathematical model describing the gear tooth geometry was developed, in which the transition curve at the tooth root was directly related to the applied machining process—either rack-type gear shaping or pinion-type gear shaping. Based on this model, a numerical procedure for calculating the bending stresses at the tooth root was formulated and verified using the finite element method (FEM). The results demonstrated high consistency between the proposed approach and FEM analysis, confirming the accuracy of the developed mathematical model and numerical methodology. The study also examined the effect of the tool fillet radius on the stress distribution in the root region. It was found that increasing the tool radius leads to a reduction in bending stresses, while the differences between the two machining methods gradually diminish. The proposed methodology offers a reliable numerical framework for assessing the strength of spur gears and can be effectively used in the design of lightweight, high-performance gear transmissions for aerospace and automotive applications. Full article

Background: Adult patients with a thin buccal cortical plate and fragile periodontal phenotype are at high risk of dehiscence, fenestration and recession during transverse orthodontic expansion. Conventional mechanics often create a cervical compression-dominant environment that exceeds the adaptive capacity of the periodontal ligament (PDL)–bone complex. Objectives: This study proposes an integrative mechanobiological model in which a skeletal-anchorage-assisted loading protocol (Bone Protection System, BPS) transforms expansion into a tension-dominant regime that favours buccal phenotype preservation. Methods: Patient-specific finite element models were used to compare conventional expansion with a BPS-modified force system. Regional PDL stress patterns and crown/apex displacement vectors were analysed to distinguish tipping-dominant from translation-dominated mechanics. A pilot CBCT proof-of-concept (n = 1 thin-phenotype adult) with voxel-based registration quantified changes in maxillary and mandibular alveolar ridge width and buccal cortical plate thickness before and after BPS-assisted expansion. The mechanical findings were integrated with current evidence on compression- versus tension-driven inflammatory and osteogenic pathways in the PDL and cortical bone. Results: FEM demonstrated that conventional expansion concentrates high cervical compressive stress along the buccal PDL and cortical surface, accompanied by bending-like crown–root divergence. In contrast, the BPS protocol redirected forces to create a buccal tensile-favourable region and a more parallel crown–apex displacement pattern, indicative of translation-dominated movement. In the proof-of-concept (n = 1) CBCT case, BPS-assisted expansion was associated with preservation or increase of buccal ridge dimensions without radiographic signs of cortical breakdown. Conclusions: A tension-dominant orthodontic loading environment generated by a skeletal-anchorage-assisted force system may support buccal cortical preservation and vestibular phenotype reinforcement in thin-phenotype patients. The proposed mechanobiological model links these imaging and FEM findings to known molecular pathways of inflammation, angiogenesis and osteogenesis. It suggests a functional biomaterial-based strategy for widening the biological envelope of safe tooth movement. Full article

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 high-speed reducers. A coupled bending–torsional–shaft dynamic model is developed, in which the time-varying mesh stiffness of cracked helical gears is calculated using an improved potential energy method. The system’s nonlinear dynamic responses under varying mesh error excitation, gear backlash, and damping ratio are numerically obtained via the variable-step Runge–Kutta method. The results reveal that under high input speed conditions, the motion of the faulted system evolves from single-period to quasi-periodic motion as bifurcation parameters change. In the stable state, fault characteristic signals are apparent, whereas under strong nonlinear vibrations and chaotic motion, they become difficult to distinguish in traditional time- and frequency-domain analyses. To address this limitation, the DBSCAN clustering algorithm is introduced, which applies machine learning to cluster the Poincaré cross-sections of the system under different motion states. This approach enables the effective classification and identification of crack-induced and fault-related noise, thereby improving the accuracy of fault detection in nonlinear dynamic gear systems. Full article

Compared to spiral bevel gear drives with localized conjugation, line contact spiral bevel gears possess a significantly larger meshing area, theoretically achieving full tooth surface contact and substantially enhancing load capacity. To accurately support the root strength calculation and parameter design of line contact spiral bevel gear drives, this paper presents a theoretical analysis and experimental study of the root bending stress of gear pairs. First, based on the analysis of the meshing characteristics of line contact spiral bevel gear pairs, the load distribution along the contact lines is investigated. Using the slicing method, the load distribution characteristics along the contact line are obtained, and the load sharing among multiple tooth pairs during meshing is further studied. Then, by applying a cantilever beam bending stress model, the root bending stress on such a gear drive is calculated. A root bending moment distribution model is proposed based on the characteristics of the line load distribution previously obtained, from which a formula for calculating root bending stress is derived. Finally, static-condition experiments are conducted to test the root bending stress. The accuracy of the proposed calculation method is verified through experimental testing and finite element analysis. The results of this study provide a foundation for designing lightweight and high-power-density spiral bevel gear drives. Full article

The manufacture of lightweight components is one of the most important requirements in the automotive and aerospace industries. Gears, on the other hand, are among the heaviest parts in terms of their total weight. Accordingly, a spur gear was considered, the body of which was configured as a lattice structure to make it lightweight. In addition, the structure was optimized by topology optimization using ProTOP software. Subsequently, the gear was manufactured by a selective laser melting process by using a strong and lightweight material, namely Ti-6Al-4V. This study defeated the problems of manufacturing orientation, surface roughness, support structure, and bending due to the high thermal gradient in the selective laser melting process. To experimentally investigate the benefits of such a lightweight gear body structure, a new test rig with a closed loop was developed. This rig enabled measurements of strains in the gear ring, hub, and tooth root. The experimental results confirmed that a specifically designed and selectively laser-melted, lightweight cellular lattice structure in the gear body can significantly influence strain. This is especially significant with respect to strain levels and their time-dependent variations in the hub section of the gear body. Full article

The involute profile is used almost exclusively in the manufacturing of spur gears. Nevertheless, in machinery design, the evaluation of environmental factors, such as energy efficiency, has become increasingly important when choosing between feasible solutions. As a result, the study of alternative profiles is gaining interest. The key novelty of this study is the comparative analysis of involute and cycloidal gear profiles with respect to frictional power losses in the tooth contact, as well as their impact on energy efficiency in spur gear transmissions. The coefficient of friction is approximated using two widely applied analytical lubrication models: the elastohydrodynamic and mixed elastohydrodynamic, both of which provide enough accurate values with a reasonable amount of computation burden in comparison with numerical methods. An additional contribution of this study is a sensitivity assessment of the energy efficiency of the cycloidal profile with regard to the auxiliary centrode diameters. This allows for an understanding of the geometrical constraints of this profile, specifically the maximum pressure angle—which is related to the radial loads applied to the shaft—and the tooth height—which is related to the bending moment at the tooth root—and hence, setting the appropriate ones to be equivalent to the involute profile. For the comparative analysis, equivalent profiles are selected based on similar tooth bending moments and radial loads supported by the shaft. After determining the centrode diameters of the cycloidal profile, the efficiency of both gear profiles and their sensitivity to gear size and gear ratio are compared. This study concludes that, for both profiles and friction analytical models, efficiency improves with increasing gear sizes and gear ratios, eventually converging to a constant value. Furthermore, both cycloidal and involute profiles exhibit comparable performance in terms of energy efficiency across both lubrication analytical models. Full article

Current gear design guidelines and standards have given little or no consideration to the increase in strength that can be achieved by using ultra-clean steels. In order to fully exploit the potential of ultra-clean steels, it is therefore necessary to use higher-quality calculation methods that combine FEM stress calculations with local strength calculations. Therefore, the aim of this paper is to extend the inclusion-based model to allow for the calculation of the tooth root bending strength of gears with different steel cleanliness. For this purpose, a material analysis of 20MnCr5 with three different degrees of cleanliness is carried out and the respective material defect distribution is determined. In order to be able to represent the determined material defect distributions of the different cleanliness grades in the inclusion-based model, the model is extended accordingly, and a sensitivity analysis is carried out on the influence of the material defect distribution functions on the tooth root bending strength calculation. Finally, the model is applied to a pulsator test to verify the applicability of the model. The results of the verification show that the calculation of the mean bending strength of gears in pulsator investigations is generally possible with the extended inclusion-based model. The inclusion-based model thus offers the potential to improve the statistical significance of pulsator test results by supplementing the limited number of practical test points with the virtual test points of the inclusion-based model. Full article

(1) Background: The in vitro study aimed to investigate mechanical characteristics of resin composites and their suitability in direct restauration of endodontically treated teeth (ETT). (2) Methods: 38 endodontically treated premolars with occlusal access cavities were directly restored using the following resin composites and adhesives: Tetric Evo Ceram^® + Syntac classic^® (n = 10), Venus Diamond^® + iBond Total-Etch^® (n = 10), Grandio^® + Solobond M^® (n = 9), Estelite^® Sigma Quick + Bond Force^® (n = 9). After thermocycling, the elastic modulus, shear-bond-strength, fracture load (Fmax) and fracture mode distribution were evaluated. Statistical analysis: one-way ANOVA, t-test, Kruskal–Wallis test; p < 0.05. (3) Results: Grandio^® showed the highest E-modulus (15,857.9 MPa) which was significant to Venus Diamond^® (13,058.83 MPa), Tetric Evo Ceram^® (8636.0 MPa) and Estelite^® Sigma Quick (7004.58 MPa). The highest shear-bond-strength was observed for Solobond M^® (17.28 MPa), followed by iBond^® (16.61 MPa), Syntac classic^® (16.41 MPa) and Bond Force^® (8.37 MPa, p < 0.05). The highest fracture load (Fmax) was estimated for ETT restored with Venus Diamond^® (1106.83 N), followed by Estelite^® Sigma Quick (1030.1 N), Tetric Evo Ceram^® (1029 N) and Grandio^® (921 N). Fracture-mode distribution did not show any significant differences. (4) Conclusions: The observed resin composites and adhesives show reliable mechanical characteristics and seem to be suitable for direct restoration of endodontically treated teeth. Full article

Orthodontic Mini-Implants have a high success rate, but it is crucial to assess the load that they bear in order to maintain their primary stability. Increasing the diameter can improve this stability, but there are limitations due to the proximity of the tooth roots. To avoid damage, smaller diameters are used, which can decrease resistance and cause permanent deformations. Objective: The objective of this study is to evaluate the influence of the diameter of Mini-Implants through bending force tests, taking into account primary stability after one and two insertions. Methods: Here, 40 Ti6AI4V alloy Mini-Implants of two different brands and diameters were divided into eight groups, half of which received one insertion in the artificial bone, and the rest received two. All were subjected to a constant bending force using an INSTRON-Electropuls E10000LT (Norwood, MA, USA) until fracture. Results: The smaller-diameter Mini-Implants were less resistant to fracture, but both were able to withstand the necessary loads produced by orthodontic movements. As for the inserts, there were no statistically significant differences. Conclusions: There is an advantage to using 1.6 mm Mini-Implants over 2.0 mm ones, as a smaller diameter does not lead to fracture due to the forces used in orthodontic treatment. Having one or two inserts did not have a statistically significant effect. Full article

The root residual stress during gear machining has a significant impact on the bending fatigue performance of the gear. The process parameters of gear hobbing (hob speed, axial feed speed, and radial cutting depth) directly affect the residual stress of the tooth root. To investigate the relationship between the process parameters of hobbing and the residual stress of the tooth root respectively, an analysis of an orthogonal and single factor was conducted in the hobbing experiment, taking into account the interactions among factors, which revealed the influence rule and primary–secondary relationship of the process parameters on the residual stress of the tooth root. The importance coefficients of the process parameters on the residual stress of the tooth root were calculated using the Least Absolute Shrinkage and Selection Operator (LASSO) method. The results indicate that the residual tensile stress at the tooth root increases with an increase in the hob speed and axial feed speed within the selected range but decreases with an increase in the radial cutting depth. The influence of the process parameters on the residual stress of the tooth root can be ranked as follows: hob speed (importance coefficient 0.460), axial feed speed (importance coefficient 0.278), and radial cutting depth (importance coefficient 0.262). This research provides a basis for improving the residual stress of the tooth root and enhancing the anti-fatigue manufacturing of gears, thus holding significant research value. Full article

This study proposes a double-crown tooth surface modification technology that improves the load-carrying capacity of non-orthogonal helical tooth surface gears. The tooth modification is determined by a modified rack-cutter, and its feed motion is related to an intentionally designed transmission error. The novelty of the tooth modification design is that the transmission error can be pre-designed. First, changing the tooth profile of the tool enables preliminary modification along the tooth profile direction; second, by modifying the interaction between the tool and the machined gear, subsequent fine adjustments are made to the contact path. This two-stage tooth modification strategy not only retains the advantages of the traditional method but also significantly improves the balance of the load distribution on the tooth surface through an original contact path modification strategy. Through systematic tooth contact analysis (TCA) and loaded tooth contact analysis (LTCA), it was verified that the new method reduces contact stress and tooth root bending stress and improves the gear’s resistance to misalignment errors. This research provides the basis and motivation for further exploring and improving this tooth profile modification technology to solve the challenges faced by more complex gear systems. Full article

Due to their versatile advantages, the use of additively manufactured components is growing. In addition, new additive manufacturing processes are constantly being developed, so that a wide range of printing processes are now available for metal. Despite the same starting material, the microstructure and thus also the final mechanical properties differ greatly compared to conventional processes. In most cases, only direction-dependent characteristic values from the uniaxial tension are used to qualify a printing process before it is used. The literature, on the other hand, demonstrates that the results are not transferable to other loading conditions. In this work, several engineering tests were integrated into a single test specimen so that they can be determined on the same specimen. The test specimen can be used to test tooth root strength, bending strength, notched bar impact energy, and thread strength depending on the mounting direction, thus representing industrial loading cases. In this study, test specimens were fabricated by conventional manufacturing (machining), L-PBF (Laser Powder Bed Fusion), and WA-DED (Wire Arc Direct Energy Deposition), and the results were compared using statistical methods. Factors to capture manufacturing influence and buildup direction were statistically validated on 316L. The work shows a benchmark with a typical initial microstructure of rolled and milled material, L-PBF, and WA-DED parts on loads close to the application and thus simplifies an industry-oriented evaluation of a new manufacturing process. Full article

This article proposes and designs a novel variable pitch adjustment device for small wind turbines. The generator spindle is designed to be hollow so that the drive rod passes through it and connects the pitch drive mechanism to the pitch actuator. The article introduces the basic structure and working principle of the pitch mechanism and verifies the feasibility of the pitch device by using 3D printing technology to produce a small-scale model. The stress analysis of the wind turbine was carried out using the unidirectional fluid–structure coupling method. The results show that the maximum equivalent stress of the pitch mechanism is 27.42 MPa, the maximum tooth surface contact stress of the gear is 38.40 MPa, and the maximum tooth root bending stress is 18.13 MPa. The rack synchronous disk, blade handle, and gear rack mechanism were designed with light weight using various optimization schemes. The results of the optimization showed that the overall mass of the pitch mechanism was reduced by 33.2%, improving the applicability of the new pitch mechanism. Full article

This study aimed to investigate the dynamic behavior of different torque archwires for fixed orthodontic treatment using an automated, force-controlled biomechanical simulation system. A novel biomechanical simulation system (HOSEA) was used to simulate dynamic tooth movements and measure torque expression of four different archwire groups: 0.017″ x 0.025″ torque segmented archwires (TSA) with 30° torque bending, 0.018″ x 0.025″ TSA with 45° torque bending, 0.017″ x 0.025″ stainless steel (SS) archwires with 30° torque bending and 0.018″ x 0.025″ SS with 30° torque bending (n = 10/group) used with 0.022″ self-ligating brackets. The Kruskal–Wallis test was used for statistical analysis (p < 0.050). The 0.018″ x 0.025″ SS archwires produced the highest initial rotational torque moment (M_y) of −9.835 Nmm. The reduction in rotational moment per degree (M_y/R_y) was significantly lower for TSA compared to SS archwires (p < 0.001). TSA 0.018″ x 0.025″ was the only group in which all archwires induced a min. 10° rotation in the simulation. Collateral forces and moments, especially F_x, F_z and M_x, occurred during torque application. The measured forces and moments were within a suitable range for the application of palatal root torque to incisors for the 0.018″ x 0.025″ archwires. The 0.018″ x 0.025″ TSA reliably achieved at least 10° incisal rotation without reactivation. Full article

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 initial crack position except for the load and material properties. In this paper, the crack propagation model of a gear is established under the considering of crack initiation location by using extended finite element method (XFEM). The model accuracy is verified by testing results of strain and fractography by conducting the single-tooth bending fatigue experiment. The influence of crack initiation locations on subsequent crack propagation behavior is analyzed. The crack length in the tooth width direction and depth direction is faster when the initial crack is located in the middle of root surface. The crack growth rate is lower for the initial crack located in the surface close to the end surface of the gear. Full article