![]() With the results of the simulation und taking into consideration the fracture characteristics determined in a SEM, a fracture analysis for fisheye failures in the tooth root fillet of high-strength gears is carried out that links different theories found in the literature. The aim is to explain certain fracture characteristics, which differ from fisheye failures of standard specimens. This paper presents a detailed FEM simulation of the stress state at a non-metallic inclusion in the tooth root fillet of such high-strength gears. However, due to the compressive residual stresses, fisheye failures at non-metallic inclusions can occur, which have an effect on the endurance fatigue strength of high-strength gears, especially in the very high cycle fatigue range. One way of reducing gear weight is to apply a shot-peening process in addition to the usual case-hardening because the higher compressive residual stresses within the material mean that the same torque values can be transmitted with smaller gears. ![]() Lightweight design has had an important role to play in recent gear developments.
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