PSI - Issue 57

Haelie Egbert et al. / Procedia Structural Integrity 57 (2024) 179–190 Haelie Egbert et al. / Structural Integrity Procedia 00 (2019) 000 – 000

190 12

5. Synchronization Error – This error includes both initial cycle synchronization error and cycle to cycle synchronization error. Initial cycle synchronization is how well aligned the initial camera frame is to the position of maximum crack opening (maximum applied force) and is a function of data acquisition internal sample clock frequency and sampling resolution of the equipment. Cycle to cycle synchronization includes these effects but also includes the variability of the cycle-to-cycle loading frequency which is a function of the high-speed controller, servo valves and machine characteristics. The equipment used in this study is high quality data acquisition controllers from National Instruments and Photron. 6. Len Aberration Errors – These errors are well described in the existing literature and relate to distortion of the image through lens due to a combination of lens defects and various physical properties of a lens. While some of these errors are accounted for or reduced via FOV calibration, the calibration cannot account for distortion in parts of the image further away from the tooth outline used for calibration. In other words, even though the tooth outline matches very well via calibration there could be distortion of the image near the center of the tooth that is unaccounted for. However, the order of magnitude of these errors is generally assumed negligible when using high quality lensing from a reputable manufacturer. In this case the lens was a Tamron SP 90 mm F/2.8. Future work to improve upon these errors should start with (1) and (2). This is because they are the most feasible and least expensive items to improve, and the relative induced error is speculated to be much higher from these sources as compared to the remaining four sources. It is important to note that both the qualitative and quantitative insights and conclusions from this study are still valid and can be used to advance the science of gear design in crack propagation modeling and structural health monitoring systems. [3] I.J. Hong, A. Kahraman, N. Anderson, An Experimental Evaluation of High-Cycle Gear Tooth Bending Fatigue Lives Under Fully Reversed and Fully Released Loading Conditions With Application to Planetary Gear Sets, Journal of Mechanical Design. 143 (20 21) 023402. https://doi.org/10.1115/1.4047687. [4] N.K. Raghuwanshi, A. Parey, Experimental measurement of spur gear mesh stiffness using digital image correlation technique, Measurement. 111 (2017) 93 – 104. https://doi.org/10.1016/j.measurement.2017.07.034. [5] P. Blais, L. Toubal, Single-Gear-Tooth Bending Fatigue of HDPE reinforced with short natural fiber, International Journal of Fatigue. 141 (2020) 105857. https://doi.org/10.1016/j.ijfatigue.2020.105857. [6] V. Savaria, F. Bridier, P. Bocher, Predicting the Effects of Material Properties Gradient and Residual Stresses on the Bendin g Fatigue Strength of Induction Hardened Aeronautical Gears, International Journal of Fatigue. 85 (2016) 70 – 84. https://doi.org/10.1016/j.ijfatigue.2015.12.004. [7] T. Masuyama, S. Yoshiizumi, K. Inoue, Quantitative Evaluation of Strain Near Tooth Fillet by Image Processing, JSME Int. J., Ser. C. 49 (2006) 1131 – 1139. https://doi.org/10.1299/jsmec.49.1131. [8] R. Pullin, A. Clarke, M.J. Eaton, K.M. Holford, S.L. Evans, J.P. McCory, Detection of Cracking in Gear Teeth Using Acoustic E mission, AMM. 24 – 25 (2010) 45 – 50. https://doi.org/10.4028/www.scientific.net/AMM.24-25.45. [9] N. Gehri, J. Mata-Falcón, W. Kaufmann, Automated crack detection and measurement based on digital image correlation, Construction and Building Materials. 256 (2020) 119383. https://doi.org/10.1016/j.conbuildmat.2020.119383. [10] M. Sánchez, C. Mallor, M. Canales, S. Calvo, J.L. Núñez, Digital Image Correlation parameters optimized for the characterization of fatigue crack growth life, Measurement. 174 (2021) 109082. https://doi.org/10.1016/j.measurement.2021.109082. [11] SAE International Surface Vehicle Recommended Practice, Single Tooth Gear Bending Fatigue Test, SAE Standard J1619. (1997). [12] J. Wheitner, D.R. Houser, Investigation of the Effects of Manufacturing Variations and Materials on Fatigue Crack Detection M ethods in Gear Teeth, NASA CR 195093. (1994). References [1] I. Hong, Z. Teaford, A. Kahraman, A comparison of gear tooth bending fatigue lives from single tooth bending and rotating gea r tests, Forschung Im Ingenieurwesen/Engineering Research. (2021). https://doi.org/10.1007/s10010-021-00510-w. [2] I.J. Hong, A. Kahraman, N. Anderson, A rotating gear test methodology for evaluation of high -cycle tooth bending fatigue lives under fully reversed and fully released loading conditions, International Journal of Fatigue. 133 (2020) 105432. https://doi.org/10.1016/j.ijfatigue.2019.105432.