Master Thesis: Development of Method for Prediction of Tooth Interior Fatigue Fracture in Gears

Transport is at the core of modern society. Imagine using your expertise to shape sustainable transport and infrastructure solutions for the future. If you seek to make a difference on a global scale, working with next-gen technologies and the sharpest collaborative teams, then we could be a perfect match. Position Description Gears are an important component of a gearbox. When designing gears, various requirements for strength, service life, power loss, and noise must be balanced. Gears for electric vehicles generally face different requirements from gears in conventional drivetrains, and the design must account for other potential failure modes. For example, gears in electric-vehicle drivetrains are subjected to more frequent changes in load direction because electric machines are often used to convert kinetic energy into electrical energy, thereby breaking the vehicle. When a gear is subjected to frequent changes in torque direction, this must be taken into account in its design. For some years, Volvo has conducted gear bending-fatigue tests on a test rig that makes it possible to apply many load-reversal cycles to rotating gears in a short time. Under some conditions, failures have initiated at the root, which is the “normal” failure mode. In other cases, tooth failure has initiated beneath the case-hardening layer, a so-called Tooth Interior Fatigue Fracture (TIFF) failure. Description Of Thesis Work The proposed thesis concerns developing a method for predicting risk of TIFF fracture in gears subjected to alternating loading with basis in prior performed tests. More specifically, this would entail:

• Literature study on TIFF fracture and similar failure mechanisms (like TFF, see ISO/TS 6336-4 for reference)
• Evaluation and analysis of results from prior performed tests (e.g. using statistical analysis methods)
• Development of method for evaluating risk of TIFF, taking into account multiaxial stress state in the subsurface material where TIFF fractures normally happen
• Validation of prior performed test data against developed method (and possibly a representative FE-model)
• (If time allows) Performance of further bending fatigue tests to expand sample space and validation of developed method against new test data

Qualifications & Key Attributes

• Master student in Engineering Physics, Mathematics, Applied Mechanics or equivalent
• Positive attitude, willing to learn, disciplined, good communication skills, humble, result oriented

Information Thesis Level: Master Language: English Starting date: 2027-01-18 Number of students: 2 Tutor : Lennart Johansson, Senior Expert Gear Specialist, Powertrain Technology, Trucks Technology & Industrial Division Last application: 8:th of November. We value your data privacy and therefore do not accept applications via mail. Who We Are And What We Believe In We are committed to shaping the future landscape of efficient, safe, and sustainable transport solutions. Fulfilling our mission creates countless career opportunities for talents across the group’s leading brands and entities. Applying to this job offers you the opportunity to join Volvo Group. Every day, you will be working with some of the sharpest and most creative brains in our field to be able to leave our society in better shape for the next generation. We are passionate about what we do, and we thrive on teamwork. We are almost 100,000 people united around the world by a culture of care, inclusiveness, and empowerment. Trucks Technology & Industrial Division hire team players who are ready to create real customer impact. Our decentralized teams work close to our customers, with speed and autonomy, to build what they truly need. Join us to collaborate on innovative, sustainable technologies that redefine how we design, build, and deliver value. Bring your curiosity, your expertise, and your collaborative energy, and together, we’ll turn bold ideas into tangible solutions for our customers and contribute to a more sustainable tomorrow.