A numerical method to predict the RCF behaviour of PVD-coated transmission gears and experimental results

This work studies the rolling contact fatigue (RCF) behaviour of case-hardened transmission gears for racing motorcycles both numerically and experimentally. Both as-produced and PVD-WC/C coated conditions are analyzed. Finite element models of the gears were developed and a calculation procedure was applied to predict their RCF life. The Ti-6Al-4 V alloy was also considered to investigate the mass decrease of the components. RCF tests were carried out in both dry and lubricated conditions. The experimental results were compared with the numerical ones to check the reliability of the predictive method proposed.