Residual Stress Distribution Design for Gear Surfaces Based on Genetic Algorithm Optimization

The rolling contact fatigue of gear surfaces in a heavy loader gearbox is investigated under various working conditions using the critical plane-based multiaxial Fatemi–Socie criterion. The mechanism for residual stress to increase the fatigue initiation life is that the compressive residual stress has a negative normal component on the critical plane. Based on this mechanism, the genetic algorithm is used to search the optimum residual stress distribution that can maximize the fatigue initiation life for a wide range of working conditions. The optimum residual stress distribution is more effective in increasing the fatigue initiation life when the friction coefficient is larger than its critical value, above which the fatigue initiation moves from the subsurface to the surface. Finally, the effect on the fatigue initiation life when the residual stress distribution deviates from the optimum distribution is analyzed. A sound physical explanation for this effect is provided. This yields a useful guideline to design the residual stress distribution.