In the scope of this work, a holistic approach for fatigue life design and testing of gearboxes under random load conditions is presented. The failure mechanisms pitting and tooth root breakage were considered particularly as they are typically the main damage mechanisms for power gearboxes. Theoretical approaches for fatigue life design, for performing shortened lifetime tests as well as for calculating tooth flank modifications for load spectra are supplemented by experimental investigations on FZG back-to-back test rigs regarding the evaluation of the remaining lifetime of pre-damaged components as well as for determining damage sums for load spectra test runs. Based on all these individual steps, a holistic model for fatigue life design and testing of gearboxes is derived and discussed. This extended fatigue life model provides a valuable contribu-tion for the holistic analysis of gearboxsystems within the development process. By applying the shown methods and calculation models properly, a significant increase of the power-to-weight ratio of gearboxes as well as a considerable reduction of the time-to-market and addi-tionally a substantial improvement of the reliability can be achieved.
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In the scope of this work, a holistic approach for fatigue life design and testing of gearboxes under random load conditions is presented. The failure mechanisms pitting and tooth root breakage were considered particularly as they are typically the main damage mechanisms for power gearboxes. Theoretical approaches for fatigue life design, for performing shortened lifetime tests as well as for calculating tooth flank modifications for load spectra are supplemented by experimental investigations o...
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