Considering a great deal of wind turbine gear failure cases, it is shown that the oxide inclusion has been one of the main reasons for the failure of the gear shaft under fatigue loading condition. In this paper, the fatigue behaviour of gears involving oxide inclusion under real operating condition is investigated. A three‐dimensional finite element model for helical gear pair applied in the middle stage of wind power increasing gearbox is established, and the fatigue life of nonmetallic inclusion zone of middle gear shaft is predicted using Miner's theory and real load spectrum of wind power growth gearbox. Then, the effects of several factors (such as the size and position of oxide inclusion and residual stress induced by manufacturing) on the fatigue life of gears with inclusion are studied. The results show that both inclusion size and position have great influence on the fatigue life of gears, and the compress residual stress will prolong the fatigue life of gears. Furthermore, the critical safety line and safety region of gears with oxide inclusion have been obtained for three representative inclusion positions. The present work is expected to provide a guidance for the engineering design and life safety evaluation of wind turbine gears.

中文翻译：

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含氧化物夹杂物的风力发电机齿轮疲劳寿命分析

考虑到大量的风力发电机齿轮故障情况，表明在疲劳载荷条件下，氧化物夹杂物是齿轮轴故障的主要原因之一。本文研究了在实际工况下含氧化物夹杂物的齿轮的疲劳行为。建立了应用于风电增速器中段斜齿轮副的三维有限元模型，并利用Miner理论和风电增速机的实际载荷谱，对中齿轮轴非金属夹杂区的疲劳寿命进行了预测。 。然后，研究了几种因素（如氧化物夹杂物的尺寸和位置以及制造引起的残余应力）对带有夹杂物的齿轮疲劳寿命的影响。结果表明，夹杂物的大小和位置对齿轮的疲劳寿命有很大的影响，压缩残余应力会延长齿轮的疲劳寿命。此外，对于三个代表性的夹杂物位置，已经获得了带有氧化物夹杂物的齿轮的临界安全线和安全区域。预期目前的工作将为风力涡轮机齿轮的工程设计和生命安全评估提供指导。