
Equation 14 is derived from first principles but also can be derived from AGMA standards by taking the forms
of relevant formulas pertinent to spur gears and setting all design factors at unity. While a similar formula could
be developed for helical gears, testing them usually represents a step between rig testing and bench testing, and
such tests are negotiated between the client and the testing laboratory.
References cited in this section
7. A.P. Boresi and O.M. Sidebottom, Advanced Mechanics of Materials, 4th ed., John Wiley & Sons, 1985
8. “Information Sheet: Geometry Factors for Determining the Pitting Resistance and Bending Strength of
Spur, Helical, and Herringbone Gear Teeth,” AGMA 908-B89 (R1995), American Gear Manufacturers
Association, 1995
Mechanical Testing of Gears
Douglas R. McPherson and Suren B. Rao, Applied Research Laboratory, The Pennsylvania State University
Specimen Characterization
Specimen characterization is a critical part of any fatigue test program because it enables meaningful
interpretation of the results. It is important to know that the specimens to be tested meet specifications, where
key parameters fall in the specified range, and what the variations are. Characterizations fall into four areas:
dimensional, surface finish/texture, metallurgical, and residual stress.
Dimensional Characterization. Basic dimensional checks include size and alignment of mounting surfaces, size
and alignment of test surfaces relative to mounting surfaces, and size and uniformity of edge breaks at the edges
of test surfaces. These checks ensure that the specimens will fit into the test rig and either ensures that stresses
will be consistent or provides data to determine variations.
The important dimensions to check on rolling contact fatigue (RCF) specimens are diameters of mounting
trunnions and test surface, total indicator reading (TIR) test surface-to-mounting trunnions, and overall length.
The important dimensions to check on the mating load rollers are inside and outside diameters, TIR inside to
outside, crown radius and location of high point of crown, and thickness. In the case of nonstandard specimens
where the entire width of the test surface is intended to make contact, the size and uniformity of the edge break
needs to be checked.
The important dimensions to check on gear specimens fall into the areas of mounting surfaces, gear functional
charts, and other specific features impacting stress. All of the gear specimens described in the following
sections are mounted on their inside diameter. Thus, inside diameter, length between end faces, and
perpendicularity of end faces to inside diameter need to be checked. For specimens with a splined bore, the
pitch diameter, or inside diameter if so specified, counts as the inside diameter for alignment checks. The gear
functional charts are developed with the gear mounted on the test mounting surfaces. Typical measurements
include lead, profile, spacing, index, and runout. Other specific items to check include diameter over wires, root
diameter, and size and uniformity of edge break at tooth ends and along the tip.
Surface Finish/Texture Characterization. It has been standard practice to specify surface finish and texture in
terms of arithmetic average surface roughness (R
a
). Because it is possible to manufacture surfaces with widely
varying load capacity, all with the same R
a
, more information than R
a
is needed to interpret data. At a minimum,
R
z
(a measure of “average” peak roughness) should also be measured. A preferable method would be to
examine surfaces with an optical interference system that maps the contour of an area rather than the traditional
line contact. Test surfaces to be subject to contact fatigue should also be examined at 10× to ensure they are
free of corrosion, dings, scratches, and so on.
Metallurgical Characterization. Both surface hardness and hardness gradients are to meet specification. For gear
specimens, hardness should be checked at the tooth half height and at the root fillet. Details of the