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Hybrid peening is proposed to be applied with objective of improving gears fatigue life with low impact on part manufacturing time. This process consists of an alternative of a conventional dual peening, but with mixing two different media classes in only one stage. A procedure to define media classes’ selection as well as mix distribution is proposed considering the objective of enhancing part lifetime, background of gear failure modes and residual stress theory, by using known residual stress profile prediction models. Results showed that it was possible to reach maximum compressive residual stress target, without being far from its depth desired.

This work is developed under the context of determining a suitable power-recirculation gear test design. Its operation parameters are determined by the usual speed values to what the Brazilian automotive transmission systems are submitted. The operating parameters generate forces that act as a frequency source, inducing mechanical vibrations to the structure. The level of the vibrations must be supervised so it does not reach values which correspond to the structure natural frequency. In such cases, resonance zones and noise at the measurement devices occur, causing wrong measurement data and, even further, structural failures. This paper analyzes the application of a method to investigate operational conditions and, eventually, redesign the rig’s main elements, to escape from resonance and noise zones. The modal analysis appears as a suitable tool for this purpose, giving as an output the description of structure natural vibration response.