Contact fatigue life forecasting model considering micro-scale subsurface stress for aerospace spiral bevel gears

Focusing on stress distribution at subsurface layer under aerospace service condition in roughness tooth flank meshing interface, a new loaded contact fatigue life forecasting model is developed by considering micro-scale surface effect for aerospace spiral bevel gears. Firstly, tooth flank modeling considering the actual manufacturing process is used for accurate tooth flank point determination having high and uniform grid density. Then, with application geometric approximation and operation, discrete convolution and fast Fourier transformation (DCFFT) based conjugate gradient (CG) method is applied to determine time-varying load distribution. While at normal direction of each point from the high-density tooth flank discretization after accurate interpolation is added the roughness height from the actual micro-scale geometric topography measurement, a tooth flank reconstruction is performed to determine the micro- scale geometric topography. Then, elastic half-space loaded contact model and DC-FFT method are employed to compute subsurface stress distribution for roughness tooth flank. Von Mises stress is selected as design variable and introduced into Zaretsky model to establish the contact fatigue life forecasting model. Finally, a spiral bevel gear set in aerospace industrial application is exercised to verify the impact of subsurface stress on contact fatigue life.