Theoretical Calculation of Residual Stress in Case-Hardened Gears with Different Thicknesses of Hardened Layer

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In this paper, the authors investigate whether stresses of gears generated by case-hardening can be calculated theoretically or not by finite element method under the assumption that the gears have different thicknesses of hardened layer and the coefficient of thermal expansion and yield stress for gear material are known. The theoretically calculated results show that a certain thickness of hardened layer gives the maximum compression residual stress on the root fillet. And the residual stresses are in approximate agreement with those measured by X-ray method. Further it is shown that the endurance limits obtained from the bending fatigue test using a pulsator are influenced by the residual stress. Therefore from this theoretical analysis and experiments the possibility that adequate thickness of hardened layer is estimated for case-hardened gears is confirmed.
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