Residual stress interaction on gear manufacturing

Abstract

© 2017 Elsevier B.V.The contribution of the entire manufacturing chain to the final residual stress state cannot be neglected. In-between processes, the stress redistribution has to satisfy the equilibrium principle. An investigation was conducted on the manufacturing processes of gears. A convergent approach isolated the effects of the final production step. The processes’ interaction is understood by a model of springs, into a self-equilibrated potential energy concept. The influence of early production stages is revealed as the residual stress integral along the depth range mostly subjected to relaxation. Named as Unstable Area of Residual Stress (UARS), it was verified between machining and heat treatment, and between shot peening and grinding. The interaction is relevant to the gear fatigue behavior. Failure mode and lifetime correspond to the depth where the interaction effects were mainly observed.

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