Mesh characteristic changes of spiral bevel gear pair with assembly errors during tooth crack propagation

Spiral bevel gears (SBGs) are often used because of their strong carrying capacity and lower vibration. However, this heightened load capacity can sometimes result in the development of tooth surface cracks. This study aims to simulate the three-dimensional propagation of cracks in SBGs under various assembly conditions and explore how the presence of cracks affects mesh characteristics. This paper investigates crack propagation in SBGs by applying principles of fracture mechanics. Employing a combination of finite element software ABAQUS and fracture mechanics software FRANC3D, the study conducts a three-dimensional analysis of crack propagation in SBGs. The study analyzes the impact of crack propagation on the lifespan and mesh characteristics of SBGs, including crack propagation morphology, transmission error, time-varying meshing stiffness (TVMS), gear life, and tooth surface force, under various assembly errors.