The contact fatigue of aviation gears has become more prominent with greater demands for heavy-duty and high-power density gears. Meanwhile, the coexistence of tooth contact fatigue damage and tooth profile wear leads to a complicated competitive mechanism between surface-initiated failure and subsurface-initiated contact fatigue failures. To address this issue, a fatigue-wear coupling model of an aviation gear pair was developed based on the elastic-plastic finite element method. The tooth profile surface roughness was considered, and its evolution during repeated meshing was simulated using the Archard wear formula. The fatigue damage accumulation of material points on and underneath the contact surface was captured using the Brown-Miller-Morrow multiaxial fatigue criterion. The elastic-plastic constitutive behavior of damaged material points was updated by incorporating the damage variable. Variations in the wear depth and fatigue damage around the pitch point are described, and the effect of surface roughness on the fatigue life is addressed. The results reveal that whether fatigue failure occurs initially on the surface or sub-surface depends on the level of surface roughness. Mild wear on the asperity level alleviates the local stress concentration and leads to a longer surface fatigue life compared with the result without wear.

随着对重载和高功率密度齿轮的需求越来越大，航空齿轮的接触疲劳问题变得更加突出。同时，齿接触疲劳损伤和齿廓磨损并存导致表面引发失效和次表面引发接触疲劳失效之间存在复杂的竞争机制。针对这一问题，基于弹塑性有限元方法建立了航空齿轮副疲劳磨损耦合模型。考虑了齿廓表面粗糙度，并使用 Archard 磨损公式模拟了其在重复啮合过程中的演变。使用 Brown-Miller-Morrow 多轴疲劳准则捕获接触表面上方和下方材料点的疲劳损伤累积。通过加入损伤变量更新了损伤材料点的弹塑性本构行为。描述了节点周围磨损深度和疲劳损伤的变化，并解决了表面粗糙度对疲劳寿命的影响。结果表明，疲劳失效最初发生在表面还是次表面取决于表面粗糙度的水平。与无磨损的结果相比，粗糙程度的轻度磨损减轻了局部应力集中并导致更长的表面疲劳寿命。结果表明，疲劳失效最初发生在表面还是次表面取决于表面粗糙度的水平。与无磨损的结果相比，粗糙程度的轻度磨损减轻了局部应力集中并导致更长的表面疲劳寿命。结果表明，疲劳失效最初发生在表面还是次表面取决于表面粗糙度的水平。与无磨损的结果相比，粗糙程度的轻度磨损减轻了局部应力集中并导致更长的表面疲劳寿命。