Experimental Study on Bending Fatigue Performance of ADI Gears Under Different Applied Load Levels.

Lijun Wang, Hui Wei, Hsinshen Ho, Bo Hu, Yangyang Li, Dongfei Wang

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Article in Materials (Basel, Switzerland), 2025. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Not yet cited in PubMed.

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5 · Who and what money

Authors and funding

6 authors.

Lijun WangSchool of Mechanical Engineering, North China University of Water Resources and Electric Power, Zhengzhou 450045, China.

Hui WeiSchool of Mechanical Engineering, North China University of Water Resources and Electric Power, Zhengzhou 450045, China.

Hsinshen HoSchool of Mechanical and Power Engineering, Zhengzhou University, Science Avenue 100, Zhengzhou 450001, China.

Bo HuSchool of Mechanical and Power Engineering, Zhengzhou University, Science Avenue 100, Zhengzhou 450001, China.

Yangyang LiSchool of Mechanical Engineering, North China University of Water Resources and Electric Power, Zhengzhou 450045, China.

Dongfei WangNational Gear Product Quality Inspection and Testing Center, China Academy of Machinery Zhengzhou Research Institute of Mechanical Engineering Co., Ltd., Zhengzhou 450001, China.

Funding

Graduate Education Reform Project of Henan Province 2023SJGLX021Ythe Water Conservancy Equipment and Intelligent Operation and Maintenance Engineering Technology Research Centre in Henan Province Yukeshi2024-01ZHONGYUAN Talent Program ZYYCYU202012112

6 · The paper itself

Abstract

As austempered ductile iron (ADI) is a key gear material for meeting the lightweight and cost-effective demands of new energy vehicles, its bending fatigue performance has a direct impact on vehicle transmission efficiency. In the present work, QTD 800 gears were subjected to bending fatigue testing using a combination of the conventional group method and the staircase method, with considerations given to fatigue life and fatigue limit at different reliability levels. Subsequently, the gears were characterized using optical microscopy and a microhardness tester to examine their metallographic structure and determine their hardness. The results indicate that the bending fatigue limits corresponding to gear reliability levels of 50%, 90%, and 99% are 390.00 MPa, 372.55 MPa, and 358.32 MPa, respectively. It was also observed that higher gear life stability corresponds to a lower sustainable fatigue limit stress. The analyses further reveal that under low loads, the main crack exhibits a relatively straight and smooth propagation trajectory, formed through the slow extension of an existing crack, whereas under high loads, the main crack displays a rough and serrated appearance, arising from the coalescence of microcracks initiated around graphite nodules.

Indexed as

ADI gearsbending fatigue testingcrack analysisfatigue performance curvesmetallographic analysis

Identifiers

PMID40870239

DOI10.3390/ma18163922

PMCPMC12387251

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LicenceCC BY

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Read under generation 80e0d062 · epoch 390. Bibliography from PubMed, PubMed Central and OpenAlex; grants from NIH RePORTER; trial links from ClinicalTrials.gov; estimates, votes and beliefs from the OpenQuestion graph.