Therefore, experimental investigations regarding high cycle fatigue have been carried out in a pulsator
test rig on gears of various sizes, materials and residual stress conditions. As a result, depending on the
existing residual stress condition, there are different levels of tooth root load carrying capacity, different
failure behaviors in high cycle fatigue and different types of damage. Especially for test variants with high
residual stresses, the size of the gear and the cleanness of the material have an impact on the tooth root
load-carrying capacity and the damage pattern.
This paper discusses the different fracture modes by means of examples. Furthermore, it presents the
influence of residual stresses, size and material cleanness on the tooth root load-carrying capacity and on
the type of tooth root fractures with crack initiation on and under the surface. These influences will be
additionally confirmed by examples of experimental test results.

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