Experimental investigation on crack propagation paths in spur gears

Spur gears subjected to bending fatigue may nucleate cracks at the tooth root fillet. In thin rim gears these cracks 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, as already pointed out by theoretical and numerical results available in literature. Aim of this work is to set up an experimental activity in order to verify the onset of the bending crack and its propagation path in spur gears with different geometries. In particular, a special device connected to a standard fatigue machine was realized to perform bending tests for both standard and thin rim gears. During bending tests, an IR thermocamera was utilized to monitor the surface thermal profile in the tooth root fillet zone.