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Research Papers: Other (Seals, Manufacturing)

Load-Independent Spin Power Losses of a Spur Gear Pair: Model Formulation

[+] Author and Article Information
S. Seetharaman

Department of Mechanical Engineering, Ohio State University, 201 West 19th Avenue, Columbus, OH 43210

A. Kahraman1

Department of Mechanical Engineering, Ohio State University, 201 West 19th Avenue, Columbus, OH 43210kahraman.1@osu.edu

1

Corresponding author.

J. Tribol 131(2), 022201 (Feb 26, 2009) (11 pages) doi:10.1115/1.3085943 History: Received June 13, 2008; Revised January 27, 2009; Published February 26, 2009

A physics-based fluid mechanics model is proposed to predict spin power losses of gear pairs due to oil churning and windage. While the model is intended to simulate oil churning losses in dip-lubricated conditions, certain components of it apply to air windage losses as well. The total spin power loss is defined as the sum of (i) power losses associated with the interactions of individual gears with the fluid, and (ii) power losses due to pumping of the oil at the gear mesh. The power losses in the first group are modeled through individual formulations for drag forces induced by the fluid on a rotating gear body along its periphery and faces, as well as for eddies formed in the cavities between adjacent teeth. Gear mesh pumping losses will be predicted analytically as the power loss due to squeezing of the lubricant, as a consequence of volume contraction of the mesh space between mating gears as they rotate. The model is applied to a unity-ratio spur gear pair to quantify the individual contributions of each power loss component to the total spin power loss. The influence of operating conditions, gear geometry parameters, and lubricant properties on spin power loss are also quantified at the end. A companion paper (Seetharaman, 2009, “Oil Churning Power Losses of a Gear Pair: Experiments and Model Validation  ,” ASME J. Tribol., 131, p. 022202) provides comparisons to experiments for validation of the proposed model.

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Copyright © 2009 by American Society of Mechanical Engineers
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Figures

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Figure 1

Definition of oil churning parameters for a gear pair immersed in oil

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Figure 2

Definition of the geometric parameters associated with the root filling power losses

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Figure 3

Illustration of a side view of fluid control volumes of the gear mesh interface at different rotational positions 0<m1<m2<m3

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Figure 4

Three-dimensional representation of a control volume showing backlash and end flow areas

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Figure 5

Geometry of two gears in mesh at an arbitrary position m

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Figure 6

Definition of the end area at an arbitrary position m

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Figure 7

Parameters used in calculation of (a) the total tooth cavity area Qc2, (b) the overlap area Qt,1j(m), and (c) the excluded area Qb,1j(m), all at an arbitrary position m

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Figure 8

Effect of (a) temperature T, (b) oil level parameter h¯, (c) face width b, and (d) gear module m̃ on total spin power loss PT

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Figure 9

Components of PT for a gear pair having m̃=2.32 mm and b=26.7, 19.5, and 14.7 mm at h¯=1.0 and 80°C; (a) Pdp, (b) Pdf, (c) Prf, and (d) Pp

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