Early Crack Propagation in Single Tooth Bending Fatigue: Combination of Finite Element Analysis and Critical-Planes Fatigue Criteria

Mechanical components, such as gears, are usually subjected to variable loads that induce multiaxial non-proportional stress states, which in turn can lead failure due fatigue. However, the material properties available forms of bending or shear fatigue limits. Multiaxial criteria be used bridge gap between data and actual loading conditions. different could results. The main goal this paper is evaluate accuracy applied real mechanical components. With respect this, five based on critical plane concept (i.e., Findley, Matake, McDiarmid, Papadopoulos, Susmel) have been investigated. These were selected because they not only assess level damage, but also predict direction crack propagation just after nucleation. Therefore, measurements (crack position direction) fractured gear samples tested via Single Tooth Bending Fatigue (STBF) tests two geometries reference. STBF configuration was numerically simulated Finite Elements (FE) analyses. results FE elaborated above-mentioned criteria. numerical compared with experimental ones. result comparison showed all agree identifying most point. Findley Papadopulus proved accurate estimating damage. Susmel criterion turns out conservative one. identification early crack, revealed appropriate.