A Surface Wear Prediction Methodology for Parallel-Axis Gear Pairs

2004 ◽  
Vol 126 (3) ◽  
pp. 597-605 ◽  
Author(s):  
P. Bajpai ◽  
A. Kahraman ◽  
N. E. Anderson
Keyword(s):  
Numerical Procedure ◽  
Surface Wear ◽  
Wear Prediction ◽  
Helical Gears ◽  
Coordinate Measurement ◽  
Mechanics Model ◽  
Manufacturing Errors ◽  
Tooth Surfaces ◽  
Parallel Axis ◽  
Gear Contact

In this study, a surface wear prediction methodology for spur and helical gears is proposed. The methodology employs a finite elements-based gear contact mechanics model in conjunction with the Archard’s wear formulation to predict wear of contacting tooth surfaces. An iterative numerical procedure is developed to account for the changes in the gear contact as the gears wear. A methodology is developed to import gear coordinate measurement machine data into the gear contact model in order to analyze gears with actual manufactured surfaces with profile and lead modifications. Results of an experimental study are presented for validation of the methodology. A set of simulations is also included to highlight the differences between gear pairs having modified and unmodified tooth surfaces, with and without manufacturing errors in terms of their wear characteristics.

A Surface Wear Prediction Model for Parallel-Axis Gear Pairs

2003 ◽  
Author(s):  
P. Bajpai ◽  
A. Kahraman ◽  
N. E. Anderson
Keyword(s):  
Prediction Model ◽  
Numerical Procedure ◽  
Surface Wear ◽  
Wear Prediction ◽  
Helical Gears ◽  
Coordinate Measurement ◽  
Mechanics Model ◽  
Tooth Surfaces ◽  
Parallel Axis ◽  
Gear Contact

In this study, a surface wear prediction model for spur and helical gears is proposed. The model employs a finite elements-based gear contact mechanics model in conjunction with the Archard’s wear formulation to predict wear of contacting tooth surfaces. An iterative numerical procedure is developed to account for the changes in the gear contact as the gears wear. A methodology is developed to import gear coordinate measurement machine data into the gear contact model in order to analyze gears with actual manufactured surfaces with profile and lead modifications. Results of an experimental study are presented for validation of the model. A set of simulations is also included to highlight the differences between gear pairs having modified and unmodified tooth surfaces, with and without manufacturing errors in terms of their wear characteristics.

Influence of Tooth Profile Deviations on Helical Gear Wear

2004 ◽  
Vol 127 (4) ◽  
pp. 656-663 ◽  
Author(s):  
A. Kahraman ◽  
P. Bajpai ◽  
N. E. Anderson
Keyword(s):  
Gear Tooth ◽  
Helical Gear ◽  
Tooth Profile ◽  
Tooth Surface ◽  
Surface Wear ◽  
Mechanics Model ◽  
Surface Slopes ◽  
Tooth Surfaces ◽  
Computation Algorithm ◽  
Gear Contact

In this study, a surface wear prediction model for helical gears pairs is employed to investigate the influence of tooth profile deviations in the form of intentional tooth profile modifications or manufacturing errors on gear tooth surface wear. The wear model combines a finite-element-based gear contact mechanics model that predicts contact pressures, a sliding distance computation algorithm, and Archard’s wear formulation to predict wear of the contacting tooth surfaces. Typical helical gear tooth modifications are parameterized by an involute crown, a lead crown, and an involute slope. The influence of these parameters on surface wear are studied within typical tolerance ranges achievable using hob/shave process. The results indicate that wear is related to the combined modification parameters of a gear pair rather than individual gear parameters. At the end, a design formula is proposed that relates the mismatch of contacting surface slopes to the maximum initial wear rate.

Correlation of Tooth Surface Wear Prediction With Experimental Results of Spur and Helical Gears in Commercial Vehicle Transmissions

2013 ◽  
Author(s):  
Carlos H. Wink
Keyword(s):  
Commercial Vehicle ◽  
Gear Tooth ◽  
Numerical Procedure ◽  
Tooth Wear ◽  
Experimental Results ◽  
Analytical Models ◽  
Tooth Surface ◽  
Wear Prediction ◽  
Vehicle Transmissions ◽  
Tooth Surfaces

Gear pair dynamic loads can increase significantly with involute profile changes caused by wear resulting in vibration and noise issues. Tooth stresses such as root stress and contact stress can also increase reducing gear life. Wear prediction is important during the design phase to minimize the effects of worn tooth surfaces on product performance. Some analytical models have been proposed to predict gear tooth wear; however published correlations of predictions with experimental results are still limited, especially from the gear industry. But they are vital to build confidence in analytical tools. This paper presents a correlation of wear predictions with experimental results of spur and helical gear pairs that are used in commercial vehicle transmissions. Four different gear lubricants were considered, and also three tooth finishes, grinding, honing, and shaving. A modified Archard’s wear model was used for wear predictions. The model combines a gear contact model and an iterative numerical procedure to account for tooth surface changes. Wear coefficients were determined from experiments. The correlation between predictions and dynamometer testing data was established.

Investigation of tooth contact deviations from the plane of action and their effects on gear transmission error

2005 ◽  
Vol 219 (5) ◽  
pp. 501-509 ◽  
Author(s):  
C H Wink ◽  
A L Serpa
Keyword(s):  
Gear Tooth ◽  
Transmission Error ◽  
Contact Analysis ◽  
Gear Transmission ◽  
Tooth Surface ◽  
Tooth Contact ◽  
Helical Gears ◽  
Influence Coefficients ◽  
Manufacturing Errors ◽  
Tooth Surfaces

In this paper tooth contact deviations from the plane of action and their effects on gear transmission error are investigated. Tooth contact deviations come from intentional modification of involute tooth surfaces such as tip and root profile relief; manufacturing errors such as adjacent pitch error, profile errors, misalignment and lead errors; and tooth elastic deflections under load, for example, bending and local contact deflections. Those deviations are usually neglected on gear tooth contact models. A procedure to calculate the static transmission error of spur and helical gears under loading is proposed. In the proposed procedure, contact analysis is carried out on the whole tooth surface, eliminating the usual assumption that tooth contact occurs only on the plane of action. Lead and profile modifications, manufacturing errors and tooth elastic deflections are considered in the calculation procedure. The method of influence coefficients is employed to calculate the tooth elastic deflections. Load distribution on gear meshing is determined using an iterative-incremental method. Results of some numerical examples of spur and helical gears are analysed and discussed. The results indicate that the tooth contact deviations from the plane of action can lead to imprecision on the gear transmission error calculation if they are not take into account. Therefore, the proposed procedure provides a more accurate calculation methodology of gear transmission error, since a global contact analysis is done.

Analysis of Transmission Errors Under Load of Helical Gears With Modified Tooth Surfaces

1997 ◽  
Vol 119 (1) ◽  
pp. 120-126 ◽  
Author(s):  
Y. Zhang ◽  
Z. Fang
Keyword(s):  
Rigid Bodies ◽  
Contact Load ◽  
Tooth Contact Analysis ◽  
Helical Gears ◽  
Transmission Errors ◽  
Proposed Model ◽  
Tooth Surfaces ◽  
Simulation Results ◽  
Meshing Characteristics ◽  
Gear Contact

This paper presents a model for the analysis of transmission errors of helical gears under load. The model accommodates the modification of tooth surfaces, gear misalignments and the deformation of tooth surfaces caused by contact load. In this model, the gear contact load is assumed to be nonlinearly distributed along the direction of the relative principal curvature between the two contacting tooth surfaces. As compared with conventional tooth contact analysis (TCA) that assumes gear surfaces as rigid bodies, the model presented in this paper provides more realistic simulation results on the gear transmission errors and other gear meshing characteristics when the tooth surfaces are deformed under load. The proposed model is applied to a pair of helical gears in the numerical example included in the paper.

scholarly journals Computerized Design and Generation of Low-Noise Helical Gears with Modified Surface Topology

1995 ◽  
Vol 117 (2A) ◽  
pp. 254-261 ◽  
Author(s):  
F. L. Litvin ◽  
N. X. Chen ◽  
J. Lu ◽  
R. F. Handschuh
Keyword(s):  
Gear Tooth ◽  
Error Function ◽  
Transmission Error ◽  
Low Noise ◽  
Surface Topology ◽  
Helical Gears ◽  
Transmission Errors ◽  
Bearing Contact ◽  
Pinion Gear ◽  
Tooth Surfaces

An approach for the design and generation of low-noise helical gears with localized bearing contact is proposed. The approach is applied to double circular arc helical gears and modified involute helical gears. The reduction of noise and vibration is achieved by application of a predesigned parabolic function of transmission errors that is able to absorb a discontinuous linear function of transmission errors caused by misalignment. The localization of the bearing contact is achieved by the mismatch of pinion-gear tooth surfaces. Computerized simulation of meshing and contact of the designed gears demonstrated that the proposed approach will produce a pair of gears that has a parabolic transmission error function even when misalignment is present. Numerical examples for illustration of the developed approach are given.

Tooth wear prediction of crowned helical gears in point contact

2019 ◽  
Vol 234 (6) ◽  
pp. 947-963
Author(s):  
Hongbing Wang ◽  
Changjiang Zhou ◽  
Bo Hu ◽  
Zhongming Liu
Keyword(s):  
Wear Resistance ◽  
Point Contact ◽  
Normal Pressure ◽  
Tooth Wear ◽  
Parameters Optimization ◽  
Operating Parameters ◽  
Wear Depth ◽  
Wear Prediction ◽  
Helical Gears ◽  
Tooth Width

A tooth wear prediction methodology for helical gears in point contact is developed to evaluate their wear resistances using a lead crown. The load distribution coefficient is proposed in accordance with the elastic approach of each contact tooth pair being equal, and contact pressure are determined, and the sliding distance is obtained by adopting a generalized moving distance model. Then, the wear depth is computed in accordance with Archard’s wear equation, and the differences in tooth wear on standard and crowned helical gears are analyzed comparatively. The effects of crowned amount, fundamental geometry, and operating parameters on the wear resistance of the crowned helical gear pair are investigated. The results reveal that the tooth wear is lower on the gear surface with a moderate crowned amount than on the standard one, and that wear depths decrease with the increase in the helix angle, normal pressure angle, normal module, tooth number, or tooth width but increase with input torque rises. Furthermore, the rational lead crown, the geometric, and operating parameters optimization can be applied to wear resistance in the gear design.

Helical Gears With Circular Arc Teeth: Simulation of Conditions of Meshing and Bearing Contact

1985 ◽  
Vol 107 (4) ◽  
pp. 556-564 ◽  
Author(s):  
F. L. Litvin ◽  
Chung-Biau Tsay
Keyword(s):  
Gear Tooth ◽  
Circular Arc ◽  
Helical Gears ◽  
Numerical Examples ◽  
Technological Method ◽  
Bearing Contact ◽  
Paper Cover ◽  
Tooth Surfaces ◽  
Center Distance

Methods proposed in this paper cover: (a) generation of conjugate gear tooth surfaces with localized bearing contact; (b) derivation of equations of gear tooth surfaces; (c) simulation of conditions of meshing and bearing contact; (d) investigation of the sensitivity of gears to the errors of manufacturing and assembly (to the change of center distance and misalignment); and (e) improvement of bearing contact with the corrections of tool settings. Using this technological method we may compensate for the dislocation of the bearing contact induced by errors of manufacturing and assembly. The application of the proposed methods is illustrated by numerical examples. The derivation of the equations is given in the Appendix.

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