Transfer of the tooth flank stress into an analogy test concept to provoke the damage pattern tooth flank fracture (TFF)

摘要

The present paper deals with the development of a concept for the investigation of the damage pattern tooth flank fracture (TFF) in an analogy test. The basis for the investigations is an analogy concept developed at WZL in the form of a double pulsator. Since TFF occur in particular at large modulus gears, which cannot be economically investigated using the back-to-back test rig, there is high potential for investigating this damage pattern using an analogy test. The aim of this work is a method for the optimization of the pulsator load sequences in order to generate an equivalent stress state between analogy and running test for large-modulus spur and helical gears. For this purpose, a simulation model of a TFF critical helical gear from a wind turbine is built up. Simultaneously, a method is being developed which optimizes the pulsator loads at the primary and secondary actuator iteratively so that the highest possible correlation of the stresses between analogy test and running test can be achieved. In addition, a variation calculation is performed for determining the optimal position of the primary actuator. The results show that comparable stress tensor sequences can be achieved by an optimized positioning of the actuators. It can be shown that the resulting stress condition in the TFF critical area of the tooth volume can be represented by the analogy test.