Original scientific paper

https://doi.org/10.21278/TOF.494073524

Study on the Impact of Fill Gap and Layer Height on Residual Stresses in Arc Cladding Layers in Remanufactured Wind Turbine Broken Gear Teeth

Qiangqiang Zhang ; School of Mechanical Engineering, Ningxia University, Yinchuan 750021, China
Yang Gao ; College of Mechatronic Engineering, North Minzu University, Yinchuan 750021, China
Fuwei Wang ; College of Mechatronic Engineering, North Minzu University, Yinchuan 750021, China
Yaowei Yong ; School of Mechanical Engineering, Ningxia University, Yinchuan 750021, China *
Mengmeng Cao ; School of Mechanical Engineering, Ningxia University, Yinchuan 750021, China

* Corresponding author.

Abstract

This study investigates residual stresses in arc cladding layers of wind turbine gear teeth via experiments and simulations. The results show that increasing the filling spacing from 1 mm to 3 mm reduces maximum tensile stress, decreases stress fluctuations, and mitigates heat accumulation. However, expanding the spacing to 4 mm intensifies stress fluctuations due to uneven heat input, establishing 3 mm as optimal spacing. Regarding the layer height, increasing from 2.5 mm to 3.5 mm reduces the top-layer tensile stress while creating a concave stress distribution in intermediate zones. At the 4 mm layer height, although the top-layer stress decreases, the intermediate-zone stress rises and transitions to tensile near the centre. The optimal combination – 3 mm spacing and 3.5 mm layer height – provides theoretical guidance for wire-arc additive manufacturing of failed wind turbine gears.

Keywords

wire arc additive manufacturing; fill gap; layer height; residual stress; finite element simulation

Hrčak ID:

340832

URI

https://hrcak.srce.hr/340832

Publication date:

10.12.2025.

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