Prediction and Evaluation of Very-high Cycle Fatigue Strength of Carburized Cr-Ni Gear Steel Based on Interior Failure Mechanism

doi:10.11901/1005.3093.2021.528

Chinese Journal of Materials Research

2023, Vol. 37

Issue (1): 55-64 DOI: 10.11901/1005.3093.2021.528

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Prediction and Evaluation of Very-high Cycle Fatigue Strength of Carburized Cr-Ni Gear Steel Based on Interior Failure Mechanism

DENG Hailong¹^,²(

), LIU Bing¹, GUO Yang¹, KANG Heming¹, LI Mingkai¹, LI Yongping¹

^1.School of Mechanical Engineering, Inner Mongolia University of Technology, Hohhot 010051, China
^2.Key Laboratory of Inner Mongolia for Advanced Manufacturing Technology, Inner Mongolia University of Technology, Hohhot 010051, China

Cite this article:

DENG Hailong, LIU Bing, GUO Yang, KANG Heming, LI Mingkai, LI Yongping. Prediction and Evaluation of Very-high Cycle Fatigue Strength of Carburized Cr-Ni Gear Steel Based on Interior Failure Mechanism. Chinese Journal of Materials Research, 2023, 37(1): 55-64.

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Abstract

To evaluate the fatigue properties of carburized Cr-Ni gear steel, very high cycle fatigue tests were carried out at room temperature by stress ratios of 0 and 0.3. The fatigue failure modes of carburized Cr-Ni gear steel can be differentiated into interior fatigue failure with fine granular area (FGA) and surface fatigue failure with surface smooth area (SSA). According to the observation results of sites of inclusions and fatigue fracture morphology of the tested steels, therewith the interior very high cycle fatigue failure mechanism is clarified. Based on the cumulative damage method and the dislocation energy method, two kinds of interior fatigue strength prediction models for carburized Cr-Ni gear steels were established by taking the formation mechanism of fine granular area and the evaluated maximum size of inclusions into consideration. Based on the relationships between the relative size of FGA and the stress intensity factor of inclusion and stress ratio, the two fatigue strength prediction models were further modified, and the l_FGA-S-N curves for the maximum size of inclusions was given. The results show that the fatigue strength prediction model based on the cumulative damage method and the dislocation energy method can be used to evaluate the interior fatigue strength of carburized Cr-Ni gear steel by various stress ratios, however the prediction accuracy of the model based on the dislocation energy method is higher.

Key words: metallic materials FGA size evaluation failure mechanism cumulative damage dislocation energy method fatigue strength predictio

Received: 13 September 2021

ZTFLH:

TG111.8

Fund: the Natural Science Foundation of Inner Mongolia Autonomous Region(2022MS05014);the Natural Science Foundation of Inner Mongolia Autonomous Region(2021LHMS05009);the Higher Education Research Program of Inner Mongolia(NJZY21306);Basic Scientific Research Business Project of Universities Directly under Inner Mongolia Autonomous Region(JY20220233);the Scientific Research Program of Inner Mongolia University of Technology(ZY202005)

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	Hailong DENG
	Bing LIU
	Yang GUO
	Heming KANG
	Mingkai LI
	Yongping LI

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https://www.cjmr.org/EN/10.11901/1005.3093.2021.528 OR https://www.cjmr.org/EN/Y2023/V37/I1/55

Table 1 Chemical composition of gear steel (mass fraction, %)

Fig.1 Microstructure of carburized Cr-Ni gear steel (a) carburized, (b) base

Fig.2 Relationship between micro-hardness and residual stress and depth

Fig.3 S-N curves of carburized Cr-Ni gear steel for stress ratios of 0 and 0.3

Fig.4 Observation of typical fracture surfaces (a) fisheye (σ_a = 575 MPa, N_f = 4254700 cycles, R = 0), (b) inclusion with FGA (σ_a = 575 MPa, N_f = 4254700 cycles, R = 0); (c) surface failure (σ_a = 650 MPa, N_f = 82100 cycles, R = 0), (d) inclusion (σ_a = 650 MPa, N_f = 82100 cycles, R = 0); (e) fisheye (σ_a = 455 MPa, N_f = 9494900 cycles, R = 0.3), (f) inclusion with FGA (σ_a = 455 MPa, N_f = 9494900 cycles, R = 0.3)

Fig.5 Depth of inclusion from surface

Fig.6 Relationships between crack sizesand σ_a

Fig.7 Relationship between R_FGA/R_inc and 1/ΔK $i n c 2$

Fig.8 Interior failure mechanism

Fig.9 Relationship between σ_b/(σ_max+σ_r)+lg(lg(R_FGA/R_inc)) and lgN_f

Fig.10 Established l_FGA-S-N curves by using GPD function; (a) cumulative damage method; (b) dislocation energy method

Table 2 Estimation of fatigue strength at the maximum inclusion size under GPD function

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