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Elastohydrodynamic Lubrication

Modeling and Analysis of the Meshing Losses of Involute Spur Gears in High-Speed and High-Load Conditions

[+] Author and Article Information
L. Chang

Fellow ASME
Department of Mechanical and
Nuclear Engineering
The Pennsylvania State University
University Park, PA 16802
Advanced Institute of Manufacturing with
High-Tech Innovations
National Chung Cheng University
Ming-Hsiung, Chia-Yi 621, Taiwan
e-mail: lxc20@psu.edu

Yeau-Ren Jeng

Fellow ASME
Advanced Institute of Manufacturing with
High-Tech Innovations
National Chung Cheng University
Ming-Hsiung, Chia-Yi 621, Taiwan
e-mail: imeyrj@ccu.edu.tw

Pay-Yau Huang

Department of Mechanical Engineering
Wufeng University
Ming-Hsiung, Chia-Yi 621, Taiwan
e-mail: py.huang@wfu.edu.tw

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the Journal of Tribology. Manuscript received July 11, 2012; final manuscript received September 22, 2012; published online December 21, 2012. Assoc. Editor: Robert L. Jackson.

J. Tribol 135(1), 011504 (Dec 21, 2012) (11 pages) Paper No: TRIB-12-1112; doi: 10.1115/1.4007809 History: Received July 11, 2012; Revised September 22, 2012

A first-principle based mathematical model is developed in this paper to analyze the meshing losses in involute spur gears operating in high-load and high-speed conditions. The model is fundamentally simple with a few clearly defined physical parameters. It is computationally robust and produces meaningful trends and relative magnitudes of the meshing losses with respect to the variations of key gear and lubricant parameters. The model is evaluated with precision experimental data. It is then used to study the effects of various gear and lubricant parameters on the meshing losses including gear module, pressure angle, tooth addendum height, thermal conductivity, and lubricant pressure-viscosity and temperature-viscosity coefficients. The results and analysis suggest that gear module, pressure angle, and lubricant pressure-viscosity and temperature-viscosity coefficients can significantly affect the meshing losses. They should be the design parameters of interest to further improve the energy efficiency in high-performance, multistage transmission systems. Although the model is developed and results obtained for spur gears, the authors believe that the trends and relative magnitudes of the meshing losses with respect to the variations of the gear and lubricant parameters are still meaningful for helical gears.

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References

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Figures

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Fig. 1

Schematic of the meshing of a pair of involute spur gears (taken from Johnson [11] with permission)

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Fig. 2

Key variables through a meshing cycle of the problem defined in Table 1

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Fig. 3

Experimental results of percentage meshing efficiency by Petry-Johnson [7]

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Fig. 4

Calculated results corresponding to the experiments of Petry-Johnson [7]

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Fig. 5

Effects of gear module: meshing loss versus numbers of gear teeth

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Fig. 6

Effects of gear module: meshing loss versus module

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Fig. 7

Effects of gear pressure angle on the meshing loss

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Fig. 8

Effects of tooth addendum height on the meshing loss

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Fig. 9

Key variables through a meshing cycle with the stub gears of A12=0.8Pd

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Fig. 10

Effects of gear thermal conductivity on the meshing loss

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Fig. 11

Effects of k1 on the cross-film thermal shear localization at x = 0 and s = si

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Fig. 12

Cross-film temperature distribution at x = 0 and s = si

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Fig. 13

Effects of lubricant pressure-viscosity sensitivity on the meshing loss

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Fig. 14

Effects of lubricant temperature-viscosity sensitivity on the meshing loss

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