Influence of high speed on crack propagation path in thin rim gears

Thin rim gears need accurate design as cracks nucleated at the tooth root fillet may propagate in a safe way (through the tooth) or in catastrophic way (through the rim). Crack propagation direction is mainly influenced by both wheel geometry parameters and crack initiation point. For specific geometry configurations, crack propagation path may be influenced also by other parameters such as the centrifugal load. For this reason, in this work the effect of centrifugal load (proportional to wheel speed), related to the bending one, has been investigated. The stress field at the tooth root fillet and near the crack has been considered to evaluate the crack initiation point and to explain the propagation direction. This research activity has been carried out by means of numerical models (traditional 2D and 3D finite elements and extended finite elements (XFEM)). Results show that both crack initiation point and crack propagation path are strongly influenced by the centrifugal load entity. This effect is mainly evident in the zone of uncertainty where usually it is not possible to correlate the crack propagation path and the backup ratio value.