| Citation: | LUAN Xiaochi, XIAO Bang, LIU Gongmin, et al. Study on the evolution of crack extension frequency characteristics under traveling wave resonance of bevel gears[J]. Journal of Aerospace Power, 2025, 40（4）：20240424 doi: 10.13224/j.cnki.jasp.20240424
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Considering the problem of crack extension and fracture failure of central transmission bevel gear of a certain type of aero-engine under actual working conditions, a combination of experimental and numerical simulation was adopted to investigate the crack extension frequency characteristic evolution law of the gear in traveling wave resonance state. Based on the traveling wave resonance theory and acoustic measurement method, fatigue characteristic experiments of normal gears and prefabricated defective gears were carried out, and the acoustic signal tracking method was adopted to make the gears always in the state of traveling wave resonance. The experimental results showed that: the cracks of prefabricated defective gears in the state of traveling wave resonance were expanded rapidly, the resonance frequency decreased continuously, and the gears cannot be tracked to the point of traveling wave resonance at the late stage of the crack expansion, and the gears were instantaneously broken. Based on the modal analysis method, a finite element model of gears with different crack scales was established, and the functional relationship between crack length and modal frequency ratio in the pre-crack expansion stage was proposed, which can accurately predict the state of crack expansion in the pre-crack expansion stage with a relative error of 0.02% or less. The simulation results showed that with the deepening of the crack, the intrinsic frequency of the two symmetric modes of the same node diameters vibration of the gear decreased at the same time, but due to the increase of the asymmetry of the gear structure, it was gradually divided into two different vibration modes, and the difference of the intrinsic frequency of the two symmetric vibration modes became larger. Comprehensive experimental and simulation results showed that the traveling wave resonance in the early stage of crack expansion led to too large crack tip stress intensity factor, which caused crack expansion; then two symmetric modes appeared alternately, the gear can not maintain the traveling wave resonance state; as the crack tip stress intensity factor was close to or more than the fracture toughness of the material leading to rapid expansion of the crack, the residual strength was insufficient, leading to transient breakage.
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