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Research Papers: Applications

An Experimental Study of Influence of Lubrication Methods on Efficiency and Contact Fatigue Life of Spur Gears

[+] Author and Article Information
J. Moss

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

A. Kahraman

Winbigler Professor
Department of Mechanical
and Aerospace Engineering,
The Ohio State University,
Columbus, OH 43210
e-mail: kahraman.1@osu.edu

C. Wink

Eaton Vehicle Group,
Galesburg, MI 49053

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received September 5, 2017; final manuscript received March 30, 2018; published online May 3, 2018. Assoc. Editor: Wang-Long Li.

J. Tribol 140(5), 051103 (May 03, 2018) (11 pages) Paper No: TRIB-17-1346; doi: 10.1115/1.4039929 History: Received September 05, 2017; Revised March 30, 2018

An experimental investigation of spur gear behavior was conducted with the aim of quantifying the impact of lubrication methods and conditions on the power losses and contact fatigue lives. Variations of dip and jet-lubrication are defined, and these behaviors were observed as a function of the lubrication conditions. Both types of measurements were performed using the same type of back-to-back test machines and the same spur gear test articles such that their evaluations can be correlated. Power loss experiments were performed under both loaded and unloaded conditions to determine both load-independent (spin) and load-dependent (mechanical) losses. Sets of long-cycle contact fatigue experiments were performed under the same lubrication conditions to determine macropitting lives in a statistically meaningful manner. Results indicate that the spin power losses are impacted by the lubrication method significantly while the mechanical losses are not influenced. Contact fatigue lives from jet-lubricated tests are comparable to those under dip-lubricated conditions ones as long as jet velocities are sufficient.

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References

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Figures

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Fig. 3

(a) Front view of gearbox with a nozzle manifold in place, (b) J1 and J4, (c) J2, and (d) J3 jet lubrication conditions

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Fig. 2

Definition of static oil level parameter in dip lubrication conditions

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Fig. 4

An example set of surface roughness profiles of a test pinion tooth: (a) brand new, (b) after D2, (c) after J2, and (d) after J4

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Fig. 1

Gear efficiency test machine

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Fig. 8

Images of baseline ground pinion failures under lubrication condition D1: (a) test #1 on tooth #9, (b) test #2 on tooth #15, (c) test #3 on tooth #9, (d) test #4 on tooth #4, (e) test #5 on tooth #12, and (f) test #6 on tooth #4

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Fig. 9

Images of baseline ground pinion failures under lubrication method J1: (a) test #1 on tooth #4, (b) test #2 on tooth #14, (c) test #3 on tooth #8, (d) test #4 on tooth #9, (e) test #5 on tooth #8, and (f) test #6 on tooth #6

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Fig. 7

Images of baseline ground pinion tooth #9 from test #3 under lubrication condition D1 at: (a) 0 M, (b) 2.09 M, (c) 4.18 M, (d) 6.26 M, (e) 8.35 M, (f) 10.44 M, (g) 12.53 M, and (h) 14.62 M cycles

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Fig. 10

Images of baseline ground pinion failures under lubrication condition J2: (a) test #1 on tooth #13, (b) test #2 on tooth #4, (c) test #3 on tooth #15, (d) test #4 on tooth #12, and (e) test #5 on tooth #3

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Fig. 11

Images of baseline ground pinion failures under lubrication method J4: (a) test #1 on tooth #2, (b) test #2 on tooth #6, (c) test #3 on tooth #8, (d) test #4 on tooth #8, (e) test #5 on tooth #10, and (f) test #6 on tooth #10

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Fig. 5

Measured gearbox total power loss at: (a) Tp=0 N·m, (b) Tp=100 N·m, (c) Tp=200 N·m, and (d) Tp=300 N·m

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Fig. 6

Measured gearbox mechanical power loss at: (a) Tp=100 N·m, (b) Tp=200 N·m, and (c) Tp=300 N·m

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Fig. 12

(a) Weibull distributions and (b) percent survival curves of data sets D1, J1, J2, and J4

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