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Friction 2020, 8(3): 553-567 https://doi.org/10.1007/s40544-019-0277-3
Research Article | Open Access | Issue | Published: 24 April 2019

Study on contact fatigue of a wind turbine gear pair considering surface roughness

Show Author's Information Heli LIU1,  Huaiju LIU1( ),  Caichao ZHU1,  Zhangdong SUN2,  Houyi BAI3
State Key Laboratory of Mechanical Transmissions, Chongqing University, Chongqing 400030, China
Hubei University of Automotive Technology, Shiyan 442002, Hubei, China
Chongqing Wangjiang Industrial Co., Chongqing, 400071, China
Keywords:
carburized gear, surface roughness, contact fatigue, residual stress, Dang Van criterion
An erratum to this article is available online at https://doi.org/10.1007/s40544-019-0297-z
Cite this article:
LIU H, LIU H, ZHU C, et al. Study on contact fatigue of a wind turbine gear pair considering surface roughness. Friction, 2020, 8(3): 553-567. https://doi.org/10.1007/s40544-019-0277-3
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Abstract Full text About this article

Contact fatigue issues become more and more crucial in gear industry as they significantly affect the reliability and service life of associated mechanical systems such as wind turbine gearboxes. The contact fatigue behavior is mostly determined by the mechanical properties of materials and stress fields near the contact area, which is further influenced by the lubrication and surface roughness due to pressure fluctuations. In this study, a numerical model incorporating the lubrication state, tooth surface roughness, residual stress, and mechanical properties of the material is developed to determine the contact fatigue behavior of a megawatt level wind turbine carburized gear. The variations of the hardness and residual stress along the depth were characterized by the Vickers hardness measurement and X-ray diffraction test, respectively. The elastohydrodynamic lubrication theory was applied to predict the contact pressure distribution, highlighting the influence of the surface roughness that stemed from the original measurement through an optical profiler. The stress histories of the studied material points during a complete contact loading cycle were fast calculated using the discrete- concrete fast Fourier transformation (DC-FFT) method. Modified Dang Van diagrams under different working conditions were determined to estimate the contact fatigue failure risk. The effect of the root mean square (RMS) value of the surface roughness on the failure risk at critical material points were discussed in detail. Results revealed that the surface roughness significantly increases the contact fatigue failure risk within a shallow area, and the maximum risk appears near the surface.


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About this article

Study on contact fatigue of a wind turbine gear pair considering surface roughness

Show Author's information Heli LIU1, Huaiju LIU1( ), Caichao ZHU1, Zhangdong SUN2, Houyi BAI3
State Key Laboratory of Mechanical Transmissions, Chongqing University, Chongqing 400030, China
Hubei University of Automotive Technology, Shiyan 442002, Hubei, China
Chongqing Wangjiang Industrial Co., Chongqing, 400071, China

Abstract

Contact fatigue issues become more and more crucial in gear industry as they significantly affect the reliability and service life of associated mechanical systems such as wind turbine gearboxes. The contact fatigue behavior is mostly determined by the mechanical properties of materials and stress fields near the contact area, which is further influenced by the lubrication and surface roughness due to pressure fluctuations. In this study, a numerical model incorporating the lubrication state, tooth surface roughness, residual stress, and mechanical properties of the material is developed to determine the contact fatigue behavior of a megawatt level wind turbine carburized gear. The variations of the hardness and residual stress along the depth were characterized by the Vickers hardness measurement and X-ray diffraction test, respectively. The elastohydrodynamic lubrication theory was applied to predict the contact pressure distribution, highlighting the influence of the surface roughness that stemed from the original measurement through an optical profiler. The stress histories of the studied material points during a complete contact loading cycle were fast calculated using the discrete- concrete fast Fourier transformation (DC-FFT) method. Modified Dang Van diagrams under different working conditions were determined to estimate the contact fatigue failure risk. The effect of the root mean square (RMS) value of the surface roughness on the failure risk at critical material points were discussed in detail. Results revealed that the surface roughness significantly increases the contact fatigue failure risk within a shallow area, and the maximum risk appears near the surface.

Keywords: carburized gear, surface roughness, contact fatigue, residual stress, Dang Van criterion

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Publication history
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Publication history

Received: 06 August 2018
Revised: 19 December 2018
Accepted: 10 January 2019
Published: 24 April 2019
Issue date: June 2020

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© The author(s) 2019

Acknowledgements

The work was supported by the National Natural Science Foundation of China (Nos. U1864210, 51775060, and 51705043) and Chongqing Research Program on Technology Innovation and Application Demonstration (No. cstc2018jszx-cyzdX0053).

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