Investigation of Crack Propagation Behaviour in Thin-Rim Gears: Experimental Tests and Numerical Simulations

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 reliability and safety of high-end equipment. In this work, the root crack propagation behavior of thin-rim gears is experimentally and numerically investigated. The crack initiation position and crack propagation path for different backup ratio gears are simulated using gear finite element (FE) models. The crack initiation position is determined using the maximum gear root stress position. An extended FE method coupled with commercial software ABAQUS is used to simulate the gear root crack propagation. The simulation results are then verified by conducting experimental tests for different backup ratio gears based on a dedicated designed single-tooth bending test device.