J. Mater. Sci. Technol. ›› 2020, Vol. 49: 157-165.DOI: 10.1016/j.jmst.2019.10.044
• Research Article • Previous Articles Next Articles
Edward Charles Henry Crawford O’ Brien, Hemantha Kumar Yeddu*()
Received:
2019-05-04
Revised:
2019-07-29
Accepted:
2019-10-31
Published:
2020-07-15
Online:
2020-07-17
Contact:
Hemantha Kumar Yeddu
Edward Charles Henry Crawford O’ Brien, Hemantha Kumar Yeddu. Multi-length scale modeling of carburization, martensitic microstructure evolution and fatigue properties of steel gears[J]. J. Mater. Sci. Technol., 2020, 49: 157-165.
Fig. 2. (a) Phase-field stress cycling simulations. Evolution of martensite volume fraction and mean von Mises equivalent stress in (b) high RA sample and (c) low RA sample. (d) Variation in the mean equivalent plastic strain with martensite volume fraction.
Fig. 3. Simulated microstructures of an austenite grain with high RA content (50 % RA) subjected to stress cycling. Microstructure (a) before the stress cycling (as-quenched), (b) after completion of loading part of stress cycle-1 in the low stress regime, (c) after completion of stress cycling in the low stress regime, (d) after completion of stress cycling in the high stress regime. Martensite variants 1, 2 and 3 are shown in red, blue and green, respectively. Areas of martensite reversion are shown by ellipses (white).
Fig. 4. Simulated microstructures of an austenite grain with low RA content (14 % RA) subjected to stress cycling. Microstructure (a) before the stress cycling (as-quenched), (b) after completion of stress cycling in the low stress regime, (c) after completion of stress cycling in the high stress regime.
Fig. 5. Spur gear (inset) designed using Inventor and the gear tooth considered for fatigue analysis (ellipse). Carburized case can be clearly seen in the single gear tooth (left). Arrow indicates the loading direction and location.
Uncarburized | Carburized | ||
---|---|---|---|
S | Nf | S | Nf |
425 | 11818 | 850 | 1 ×106 |
396 | 17150 | 900 | 3.5 ×105 |
365 | 46349 | 1000 | 7.5 ×104 |
327 | 129619 | 1100 | 1.9 ×104 |
300 | 294496 | 1100 | 8.7 ×104 |
279 | 449772 | 1200 | 4.8 ×103 |
262 | 733053 | 1300 | 1.5 ×103 |
Table 1 Experimental data of stress (S) (in MPa) and the number of cycles to failure (Nf) used in fatigue analysis of uncarburized [43] and carburized [25] gear with 0.9 mm case depth using Ansys.
Uncarburized | Carburized | ||
---|---|---|---|
S | Nf | S | Nf |
425 | 11818 | 850 | 1 ×106 |
396 | 17150 | 900 | 3.5 ×105 |
365 | 46349 | 1000 | 7.5 ×104 |
327 | 129619 | 1100 | 1.9 ×104 |
300 | 294496 | 1100 | 8.7 ×104 |
279 | 449772 | 1200 | 4.8 ×103 |
262 | 733053 | 1300 | 1.5 ×103 |
Low RA | High RA | ||
---|---|---|---|
S | Navg | S | Navg |
1750 | 9 ×103 | 2100 | 1.5 ×104 |
1500 | 1.95 ×104 | 1950 | 2.17 ×104 |
1250 | 7.33 ×104 | 1650 | 2.2 ×104 |
1100 | 1.5 ×105 | 1350 | 5.93 ×104 |
950 | 2.38 ×105 | 1100 | 8.7 ×104 |
900 | 7 ×105 | 900 | 5.13 ×105 |
800 | 2.75 ×106 | 800 | 3.39 ×106 |
NA | NA | 750 | 6.41 ×106 |
NA | NA | 700 | 6.73 ×106 |
NA | NA | 650 | 107 |
Table 2 Experimental data of stress (S) (in MPa) and average number of cycles to failure (Navg) used in fatigue analysis of gears with different RA content using Ansys [3].
Low RA | High RA | ||
---|---|---|---|
S | Navg | S | Navg |
1750 | 9 ×103 | 2100 | 1.5 ×104 |
1500 | 1.95 ×104 | 1950 | 2.17 ×104 |
1250 | 7.33 ×104 | 1650 | 2.2 ×104 |
1100 | 1.5 ×105 | 1350 | 5.93 ×104 |
950 | 2.38 ×105 | 1100 | 8.7 ×104 |
900 | 7 ×105 | 900 | 5.13 ×105 |
800 | 2.75 ×106 | 800 | 3.39 ×106 |
NA | NA | 750 | 6.41 ×106 |
NA | NA | 700 | 6.73 ×106 |
NA | NA | 650 | 107 |
Fig. 6. ANSYS results of fatigue life of (a) uncarburized and (b) carburized gear tooth with case depth of 0.9 mm under a force of 50 kN at 45o with X-axis, (c) corresponding equivalent alternating stress of gear tooth shown in (b).
Fig. 7. ANSYS results of (a) equivalent alternating stress and (b) von Mises equivalent stress in gear tooth with a carburized case containing high RA content under 10 kN force at 45o with X-axis.
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