Bending Fatigue Life Simulation and Experimental Validation of Carburized Spur Gears Based on Geometric Design Parameters

A simulation model was developed to predict the bending fatigue life of carburized spur gears. The crack initiation location and life were estimated using a strain‐life approach with a multilayer model, and the crack propagation life was determined using the Paris–Erdoğan equation based on the linear elastic fracture mechanics approach and the separating morphing and adaptive remeshing technology (SMART). The present study investigates the effect of gear design parameters, including the pressure angle, profile shift, and tooth width, on tooth root fracture. The final step in the validation process entailed the use of single‐tooth bending fatigue (STBF) experiments to assess the reliability of the simulation results. Consequently, the findings from comprehensive simulation and experimental investigations have demonstrated that augmenting the pressure angle results in substantial enhancements in root crack propagation and fatigue life. The predicted bending fatigue life, crack initiation, and propagation demonstrate a strong correlation with experimental findings.