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Research Papers: Elastohydrodynamic Lubrication

Mixed Elastohydrodynamic Lubrication With Three-Dimensional Machined Roughness in Spiral Bevel and Hypoid Gears

[+] Author and Article Information
Wei Pu, Dong Zhu

School of Aeronautics and Astronautics,
Sichuan University,
Chengdu 610065, China

Jiaxu Wang

School of Aeronautics and Astronautics,
Sichuan University,
Chengdu 610065, China
Research Center of Electromechanical
Transmission and Delivery Equipment,
Chongqing University,
Chongqing 400044, China
e-mail: cquwjx@foxmail.com

Rongsong Yang

School of Manufacturing Science
and Engineering,
Sichuan University,
Chengdu 610065, China

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received November 9, 2014; final manuscript received March 13, 2015; published online May 6, 2015. Assoc. Editor: Xiaolan Ai.

J. Tribol 137(4), 041503 (Oct 01, 2015) (11 pages) Paper No: TRIB-14-1274; doi: 10.1115/1.4030185 History: Received November 09, 2014; Revised March 13, 2015; Online May 06, 2015

Spiral bevel and hypoid gears are key components widely used for transmitting significant power in various types of vehicles and engineering machineries. In reality, these gear surfaces are quite rough with three-dimensional (3D) topography that may significantly influence the lubrication formation and breakdown as well as components failures. Previous spiral bevel and hypoid gears lubrication studies, however, were limited mostly to cases under the full-film lubrication condition with smooth surfaces. In the present study, a comprehensive analysis for gearing geometry, kinematics, mixed lubrication performance, and friction and interfacial flash temperature in spiral bevel and hypoid gears is developed based on a recently developed mixed elastohydrodynamic lubrication (EHL) model that is capable of handling practical cases with 3D machined roughness under severe operating conditions and considering the effect of arbitrary entrainment angle. Obtained results from sample cases show that the simulation model developed can be used as an engineering tool for spiral bevel and hypoid gears design optimization and strength prediction.

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Figures

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Fig. 1

Geometrical relation for mixed EHL model

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Fig. 2

Geometrical relation between gear and pinion

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Fig. 3

Contact geometrical relation between gear and pinion

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Fig. 4

Geometrical model of spiral bevel and hypoid gears

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Fig. 5

Contact pattern and transmission errors on gear tooth surface

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Fig. 6

Variations of radii of curvature

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Fig. 7

Variation of entraining velocity and sliding velocity

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Fig. 8

Contact load coefficient at each meshing point

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Fig. 9

3D surface profiles

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Fig. 10

Solution domain for film thickness and pressure calculation

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Fig. 11

Film thickness and pressure contours for a pair of gear teeth from beginning to the end of engagement

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Fig. 12

Solution domain for friction and flash temperature calculation

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Fig. 13

Flash temperature contours for a pair of gear teeth from beginning to the end of engagement

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Fig. 14

Contact load ratio, λ ratio, and friction coefficient as functions of rotation angle over the entire transition

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Fig. 15

Film thickness, pressure distribution, and flash temperature distribution contours for engaging-in point

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Fig. 16

Variations of λ ratio with different rotational speeds and variations of thickness distribution contours for engaging-in point

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Fig. 17

Variations of contact load ratio with different rotational speeds and variations of pressure distribution contours for engaging-in point

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Fig. 18

Variations of friction coefficient with different rotational speeds and variations of flash temperature distribution contours for engaging-in point

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