The VCCT-method includes calculation of fracture mechanics data along the path. Given from the distributions of the accumulated plastic strain, the lifetime shares no significant difference when the frictional coefficient f ranging in 0.04-0.06.When the crack path is known, the Virtual Crack Closure Technique (VCCT) method using interface layer elements along expected crack path I available. The results show that the lifetime of crack propagation decreases significantly when the external load T increasing from 100 N m to 150 N m. The influences of the frictional coefficient and external torque on the crack propagation lifetime are also discussed. In addition, different sizes of the elements around the subsurface crack are compared in this paper. During this process, the demonstration from a subsurface crack to a spall can be uncovered. The calculation of the total cycles of the elements is proposed based on the time-varying accumulated plastic strain, which then will be used to calculate the subsurface crack propagation lifetime. The three-dimensional gear FEA dynamic model with the subsurface crack is built through dividing the gears into several small elements. Such that, the accumulated plastic strain is selected to calculate the subsurface crack propagation lifetime from the three-dimensional FEA model through ANSYS Workbench transient analysis. When choosing stress intensity factor, the high compressive stress suppresses Mode I stress intensities and severely reduces Mode II stress intensities in the heavily loaded lubricated contacts. In this paper, the heavy loads are applied to the gear system. The subsurface crack propagation lifetime is the number of cycles remaining for a spall to appear, which can be obtained through either stress intensity factor or accumulated plastic strain analysis. The subsurface crack propagation is one of the major interests for gear system research.
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