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<p>The demand for lighter and more powerful gearboxes is leading to an increase in power density. Planetary gearboxes are commonly used due to their high gear ratios with low space and weight requirements, making them suitable for various aerospace applications, including safety-critical ones. This necessitates high component safety validation requirements from aviation authorities, which typically involve both computational and experimental validation. Due to the high costs of traditional ring gear test rig investigations, this study develops an alternative method to determine the fatigue strength of spur ring gears, specifically focusing on flank bending fracture. To develop this method and understand the damage cause, the stress during operation is analysed using finite element methods, alongside analytical calculations examining how the macro-geometry influences flank bending fracture. The developed method uses a&#xa0;pulsator fixture to secure the spur ring gear accurately while considering the contact conditions. The robustness and repeatability of this method are assessed by simulating stress changes from manufacturing and assembly variations. Experimental tests validate the investigation method concerning the generated damage type. Results indicate that critical bending stress conditions can be achieved using the developed test method in a&#xa0;standard pulsator. Additionally, analytical findings suggest that the risk of bending fracture increases with higher negative addendum modification in ring gears.</p>

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Cost-effective test method for determining the fatigue strength of ring gears

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年9月6日

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  • Christian Eggert,
  • Dieter Mevissen,
  • Johannes Bauer,
  • Christian Westphal,
  • Christian Brecher

摘要

The demand for lighter and more powerful gearboxes is leading to an increase in power density. Planetary gearboxes are commonly used due to their high gear ratios with low space and weight requirements, making them suitable for various aerospace applications, including safety-critical ones. This necessitates high component safety validation requirements from aviation authorities, which typically involve both computational and experimental validation. Due to the high costs of traditional ring gear test rig investigations, this study develops an alternative method to determine the fatigue strength of spur ring gears, specifically focusing on flank bending fracture. To develop this method and understand the damage cause, the stress during operation is analysed using finite element methods, alongside analytical calculations examining how the macro-geometry influences flank bending fracture. The developed method uses a pulsator fixture to secure the spur ring gear accurately while considering the contact conditions. The robustness and repeatability of this method are assessed by simulating stress changes from manufacturing and assembly variations. Experimental tests validate the investigation method concerning the generated damage type. Results indicate that critical bending stress conditions can be achieved using the developed test method in a standard pulsator. Additionally, analytical findings suggest that the risk of bending fracture increases with higher negative addendum modification in ring gears.