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Determination of the optimal coverage for heavy-duty-axle gears in shot peening

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Abstract

Pitting and wear often appear on heavy-duty-axle gears due to their harsh working conditions, such as high torques, high loads, and poor lubrication. Shot peening is a popular surface strengthening method for gears. In order to ensure complete coverage during shot peening, 100~200% coverage is usually prescribed for most gears. However, it is difficult to effectively improve the contact fatigue and wear resistance of heavy-duty-axle gears. Generally, increasing shot peening coverage can heighten the compressive residual stress for prolonging the service lifetime of gears, whereas high coverage levels may cause the deterioration of surface roughness, thus increasing the noise and vibration of gears. To address this issue, this paper deals with the determination of optimal coverage for heavy-duty-axle gears by experimental tests. The influence of shot peening coverage on the surface integrity of gears is analyzed in terms of residual stress, microhardness, surface morphology, and microstructure. The results show that the maximum compressive residual stress increases first and then keeps stable with the increase of coverage, and the maximum value is − 1172.10 MPa. The microhardness peak increases obviously in the beginning and then slowly rises with the increase of coverage, and the maximum value is 747.5 HV1.0. The surface roughness (Ra) decreases initially and then enhances with the increase of coverage, and the minimum value is 0.99 μm under the coverage of 1000%. The crystallite size can be refined from 36.88 to 28.79 nm by shot peening. The dislocation density increases with the increase of coverage, and the maximum value is 3.70 × 1016 m−2. Numerous damages (microscalings, spallings) occur on the treated gear tooth flank affecting the residual stress distribution and roughness under high coverage levels. Meanwhile, the wear behavior of gear steels is investigated, and the wear test results show that shot peening with the coverage of 1000% can lead to a better wear resistance. Taking into consideration of surface integrity and wear test results, the coverage of 1000% is the optimal coverage for heavy-duty-axle gears in shot peening.

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Acknowledgements

The authors would like to thank Mr. Zhou Jibo, Hande axle (Zhuzhou) Gear Co., Ltd., for the provision of shot peening treatment.

Funding

This work was supported by the National Natural Science Foundation of China (grant no. 52075552, 51805552, 51805555), the Innovation and Entrepreneurship Technology Investment Project of Hunan Province (grant no. 2019GK5032), and the Fundamental Research Funds for the Central Universities of Central South University (grant no. 512191021).

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Authors and Affiliations

  1. State Key Laboratory of High Performance Complex Manufacturing, College of Mechanical and Electrical Engineering, Central South University, Changsha, 410083, People’s Republic of China

    Hongzhi Yan, Pengfei Zhu, Zhi Chen, Hui Zhang & Yin Zhang

  2. Kaifeng University, Kaifeng, 475004, People’s Republic of China

    Pengfei Zhu

  3. Central South University of Forestry and Technology, Changsha, 410004, People’s Republic of China

    Yu Zhang

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  1. Hongzhi Yan
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Contributions

Hongzhi Yan: conceptualization, funding acquisition, formal analysis, methodology, investigation, writing; Pengfei Zhu: data curation, investigation, resources, formal analysis, writing; Zhi Chen: funding acquisition, investigation, methodology, validation; Hui Zhang: data curation, investigation; Yin Zhang: data curation; Yu Zhang: data curation, funding acquisition.

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Correspondence to Zhi Chen.

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Yan, H., Zhu, P., Chen, Z. et al. Determination of the optimal coverage for heavy-duty-axle gears in shot peening. Int J Adv Manuf Technol 118, 365–376 (2022). https://doi.org/10.1007/s00170-021-07964-w

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