Simulation and experimental research on the failure mechanism of thin-walled gear rings

In order to meet engineering requirements and reduce the quality of transmission systems, thin-walled gear rings are gradually being used instead of traditional gears in engineering practice. Compared to ordinary gears, thin-walled gear rings have been significantly optimized in terms of structure and performance. However, due to the influence of dynamic meshing loads and other factors, thin-walled gear rings still suffer from problems such as poor rigidity, large machining deformation, and difficulty in controlling machining accuracy, which largely leads to high cycle fatigue of thin-walled gear rings. This article uses ABAQUS numerical simulation software to establish a finite element model of thin-walled gear rings as the research object. Based on the experimental results, the effectiveness of the simulation model was verified. Then analyzes the contact stress of thin-walled gear rings under no assembly error and with assembly error, respectively. At the same time, the influence of the carburized layer on its contact stress was further analyzed through simulation results. It can be seen from the simulation results that the maximum contact stress generated is the smallest when the thickness of the carburized layer is 0.8–1.0 mm. The contact stress of the thin-walled gear ring without assembly error is smaller than that of the thin-walled gear ring with assembly error.