Predicting the Residual Life of Spur Gears Using the SED Method

Ensuring sustainability in the industrial sector is a global priority, encompassing environmental, economic, and social dimensions. Achieving this objective requires the development of efficient strategies for product value retention, including numerical finite element (FE) models to predict component life and optimize resource utilization. For spur gears, as an example, accurate FE models are essential to replicate experimental behavior and estimate the number of cycles to failure (Nf) under operational loads. This study applies the local average strain energy density (SED) method to predict the residual life, that is, Nf, of a spur gear under varying operational loads ranging from 68 kN to 95 kN. A systematic approach was adopted: (i) developing geometric and FE model (using 2-D plane strain elements) of the gear to replicate an existing experimental setup, (ii) determining a suitable control radius R0 to define the control volume for SED calculation, and (iii) validating the FE model against experimental data. The use of R0 was instrumental in accurately capturing the energy density distribution, enabling precise residual life predictions. Results showed good agreement between SED values and experimental data, confirming that higher load levels led to increased SED values, which in turn resulted in lower Nf.