Improve wind gears bending performance by means of IGS (Improved gear surface)

Gearbox power density plays a decisive role in wind energy competitiveness. As wind turbines become larger to reduce the levelized cost of energy (LCOE), bending fatigue plays a higher role in gearbox design. Shot peening (SP) has been introduced frequently as a technique to increase wind gearbox bending capacity, but other techniques, such as root grinding (RG) and superfinishing (SF), remain insufficiently explored. This paper in-vestigates the tooth root bending strength of the case-carburized gears of a normal modulemn = 10 with different root finishing conditions. The results show no relevant influence of SF after SP. In contrast, RG prior to SP shows a potential capacity increase. However, high cycle subsurface failures must be considered for this potential ca-pacity increase.

Automated summary

Gearbox power density is crucial for wind energy competitiveness. As wind turbines increase in size to lower the cost of energy, the role of bending fatigue in gearbox design becomes more significant. While shot peening is commonly used to enhance bending capacity, other techniques like root grinding and superfinishing have not been fully explored. This study investigates the tooth root bending strength of carburized gears under different root finishing conditions and finds that superfinishing has no significant impact after shot peening. On the other hand, root grinding prior to shot peening shows potential for increased bending capacity, but the possibility of high cycle subsurface failures must be considered.