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Research Papers: Applications

An Experimental Investigation of Churning Power Losses of a Gearbox

[+] Author and Article Information
J. Polly, A. Kahraman

Department of Mechanical
and Aerospace Engineering,
The Ohio State University,
Columbus, OH 43210

D. Talbot

Department of Mechanical
and Aerospace Engineering,
The Ohio State University,
Columbus, OH 43210
e-mail: talbot.11@osu.edu

A. Singh, H. Xu

General Motors Powertrain,
Pontiac, MI 48390

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received September 8, 2017; final manuscript received October 30, 2017; published online January 24, 2018. Assoc. Editor: Sinan Muftu.

J. Tribol 140(3), 031102 (Jan 24, 2018) (8 pages) Paper No: TRIB-17-1350; doi: 10.1115/1.4038412 History: Received September 08, 2017; Revised October 30, 2017

In this study, load-independent (spin) power losses of a gearbox operating under dip-lubrication conditions are investigated experimentally using a final-drive helical gear pair from an automotive transmission as the example system. A dedicated gearbox is developed to operate a single gear or a gear pair under given speed and temperature conditions. A test matrix that consists of sets of tests with: (i) a single spur, helical gears, or disks with no teeth and (ii) helical gear pairs is executed at various temperatures, immersion depths, and pinion positions relative to its mating gear. Power losses from single gear and gear pair at identical operating conditions are compared to quantify the components of the total spin loss in the form of losses due to gear drag, gear mesh pocketing, and bearings and seals.

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References

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Figures

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Fig. 4

Parameters defining of the static oil level parameter h¯

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Fig. 3

Circumferential pinion position angles ϕ achievable by the test gearbox

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Fig. 2

Cross-sectional drawings of the test gearbox (a) with both gears assembled and (b) with only the ring gear assembled

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Fig. 1

(a) A view of the assembled test gearbox with front and top covers removed and (b) the test gear pair

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Fig. 10

Effect of gear teeth on single gear P¯s within a range of Ωr at (a) h¯=0.05, (b) h¯=0.5, (c) h¯=1.0, and (d) h¯=2.0 at 60 °C

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Fig. 5

Helical gear, spur gear, and the ring gear blank with no teeth

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Fig. 6

Repeatability of P¯s measurements with a single ring gear operated at 60 °C and h¯=1.0

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Fig. 9

Effect of bulk lubricant temperature on single gear P¯s at (a) h¯=1.0 and (b) h¯=1.5

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Fig. 11

Effect of ϕ on gear pair P¯s within a range of h¯ at (a) Ωr=500 rpm, (b) Ωr=1000 rpm, (c) Ωr=1500 rpm, and (d) Ωr=2000 rpm at 90 °C

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Fig. 12

Components of gear pair P¯s at (a) ϕ=0 deg and h¯=0.5, (b) ϕ=0 deg and h¯=1.5, (c) ϕ=90 deg and h¯=0.5, (d) ϕ=90 deg and h¯=1.5, (e) ϕ=180 deg and h¯=0.5, and (f) ϕ=180 deg and h¯=1.5

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Fig. 7

Measured input shaft bearing and seal power loss from wet and dry bearing loss tests at 60 °C. Also shown are the comparisons formulae of Ref. [20].

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Fig. 8

Influence of (a) speed and (b) oil level on single gear P¯s at 60 °C

Tables

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