An Integrated Approach for the Prediction of Fatigue Crack Paths in Face Gears for Aerospace Transmissions

In the present paper, an integrated approach for the analysis of fatigue crack propagation paths of cracks originating from tooth root in face gears for aerospace transmissions is presented. A modelling tool has been developed, in order to automatically generate FEM meshes suitable for the calculation of the stress field at the tooth root, once geometrical characteristics of gears are given. 3D planar cracks at the tooth root have been modelled and the stress intensity factors have been derived by means of FEM calculations. Three different types of gear blank design have been analysed: in all cases, the predicted crack paths are directed towards the removal of a single tooth while the rim does not seem to be affected by crack propagation.