A spalling evolution model for time-varying mesh stiffness evaluation and service life prediction of gears

Spalling is one of the most common contact fatigue failure modes on gear face. Although there are some prediction models for spalling formation, few prediction models have previously addressed the evolution from initial defects to spalling cavities. In this paper, a damage-connectivity spalling model (DCSM) is proposed to describe the formation and evolution of multiple irregular spalling cavities on the tooth face deriving from the initial defects. Subsequently, a type of TVMS-based indicator is established to represent the evolutionary severity of irregular spalling cavities. Finally, a service life prediction method is developed based on the proposed indicators. The correctness of the proposed DCSM model is verified by comparison with the extant gear spalling experiments. The effects of working load, depth ratio and quantify ratio of initial defect groups on the service life are discussed, which contributes to the service life improvements of gear pairs in the design stage.