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TECHNICAL PAPERS

A Surface Wear Prediction Methodology for Parallel-Axis Gear Pairs

[+] Author and Article Information
P. Bajpai

The University of Toledo, Toledo, OH 43607

A. Kahraman

The Ohio State University, Columbus, OH 43210e-mail: kahraman.1@osu.edu

N. E. Anderson

General Motors Powertrain, Wixom, MI 48393

J. Tribol 126(3), 597-605 (Jun 28, 2004) (9 pages) doi:10.1115/1.1691433 History: Received January 14, 2003; Revised July 10, 2003; Online June 28, 2004
Copyright © 2004 by ASME
Topics: Wear , Gears , Pressure
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References

Choy,  F. K., Polyshchuk,  V., and Zakrajsek,  J. J., Handschuh,  R. F., and Townsend,  D. P., 1996, “Analysis of the Effects of Surface Pitting and Wear on the Vibration of a Gear Transmission System,” Tribol. Int., 29, pp. 77–83.
Mackaldener, M., Flodin, A., and Andersson, S., 2001, “Robust Noise Characteristics of Gears Due to their Applications, Manufacturing Errors and Wear,” JSME International Conference on Motion and Power Transmission, MPT 2001, Fukuoka, Japan, 21–26.
Kuang,  J. H., and Lin,  A. D., 2001, “The Effect of Tooth Wear on the Vibration Spectrum of a Spur Gear Pair,” ASME J. Vibr. Acoust., 123, pp. 311–317.
Chen, Y., and Matubara, M., 2001, “Effect of Automatic Transmission Fluid on Pitting Fatigue Strength of Carborized Gears,” JSME International Conference on Motion and Power Transmission, MPT 2001, Fukuoka, Japan, 151–156.
Cioc,  C., Cioc,  S., Kahraman,  A., and Keith,  T. G., 2002, “A Deterministic Elastohydrodynamic Lubrication Model of High-Speed Transmission Components,” Tribol. Trans., 45, pp. 556–562.
Wu,  S., and Cheng,  H. S., 1993, “Sliding Wear Calculation in Spur Gears,” ASME J. Tribol., 115, pp. 493–503.
Flodin,  A., and Andersson,  S., 1997, “Simulation of Mild Wear in Spur Gears,” Wear, 207, pp. 123–128.
Flodin,  A., and Andersson,  S., 2000, “Simulation of Mild Wear in Helical Gears,” Wear, 241, pp. 123–128.
Rabinowicz, E., 1995, Friction and Wear of Materials, 2nd ed., John Wiley, New York.
Archard,  J. F., 1953, “Contact of Rubbing Flat Surfaces,” J. Appl. Phys., 24, pp. 981–988.
Hsu,  S. M., Shen,  M. C., and Ruff,  A. W., 1997, “Wear Prediction of Metals,” Tribol. Int., 30, pp. 377–383.
Williams,  J. A., 1999, “Wear Modeling: Analytical, Computational and Mapping: A Continuum Mechanics Approach,” Wear, 225, pp. 1–17.
Zhao,  Y. W., Liu,  J. J., and Zheng,  L. Q., 1992, “The Friction and Wear Model of Steels and their Probable Statistic Calculations,” Tribol. Trans., 35, pp. 673–678.
Kato,  K., 1997, “Abrasive Wear of Metals,” Tribol. Int., 30, pp. 333–338.
Sawyer,  W. G., 2001, “Life Prediction for a Simple Cam Including Couple Evolution of Wear and Load,” Lubr. Eng., September, pp. 31–36.
Priest,  M., Dowson,  D., and Taylor,  C. M., 1999, “Predictive Wear Modeling of Lubricated Piston Rings in a Diesel Engine,” Wear, 231, pp. 89–101.
Flodin,  A., and Andersson,  S., 2001, “A Simplified Model for Wear Prediction in Helical Gears,” Wear, 249, pp. 285–292.
Wagaj,  P., and Kahraman,  A., 2002, “Effect of Tooth Profile Modifications on Helical Gear Durability,” ASME J. Mech. Des., 124, pp. 501–510.
Krantz,  T., and Kahraman,  A., 2004, “An Experimental Investigation of the Influence of the Lubricant Viscosity and Additives on Gear Wear,” Tribol. Trans., 47, pp. 138–148.
Yuksel,  C., and Kahraman,  A., 2003, “Dynamic Tooth Loads of Planetary Gear Sets Having Tooth Profile Wear,” Mech. Mach. Theory, accepted for publication.
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Bajpai, P., 2002, “A Wear Prediction Model for Parallel-Axis Gear Pairs,” M.S. thesis, The University of Toledo, Toledo, OH.

Figures

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Methodology used for the computation of wear
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A three-dimensional contact mechanics model of the example gear pair 22
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Basic involute gear parameters and the coordinate frame
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Illustration of sliding distance of a point ap on gear p at different positions r
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Illustration of the change of contact pressure (Pijκ)p of a point ij as a function or r
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Wear depth of gear p having no tooth surface modifications after geometry updates of (a) κ=3 and (b) κ=8;εκ=2 μm
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Wear depth of gear g having no tooth surface modifications after geometry updates of (a) κ=3 and (b) κ=8;εκ=2 μm
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Initial surfaces of (a) gear p and (b) gear g of a modified pair
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Worn surfaces of (a) gear p and (b) gear g having tooth surface modifications after geometry update of κ=8;εκ=2 μm
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Cumulative pressure contours of gear p, (a) (Pij0)p and (b) (Pij8)pκ=2 μm
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Tooth surfaces of gear p (a) initial measured surface having both tooth surface modifications and manufacturing errors, and (b) worn surface after κ=8;εκ=2 μm
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Tooth surfaces of gear g (a) initial measured surface having both tooth surface modifications and manufacturing errors, and (b) worn surface after κ=8;εκ=2 μm
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Worn surfaces of gear p of test-1 after 27 million input cycles: (a) measurement, and (b) prediction
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Comparison of measured and predicted maximum wear depth values as a function of input cycles; k=9.65(10)−19 m2/N

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