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.
Issue Section:
Elastohydrodynamic Lubrication
References
1.
Martin
, H. M.
, 1916
, “Lubrication of Gear Teeth
,” Engineering
, Vol. 102
, London
, pp. 119
–121
.2.
Zhu
, D.
, and Wang
, Q.
, 2011
, “Elastohydrodynamic Lubrication: A Gateway to Interfacial Mechanics―Review and Prospect
,” ASME J. Tribol.
, 133
(4
), p. 041001
.10.1115/1.40044573.
Gu
, A.
, 1973
, “Elastohydrodynamic Lubrication of Involute Gears
,” ASME J. Manuf. Sci. Eng.
, 95
(4
), pp. 1164
–1170
.10.1115/1.34382654.
Wang
, K. L.
, and Cheng
, H. S.
, 1981
, “A Numerical Solution to the Dynamic Load, Film Thickness and Surface Temperature in Spur Gears, Part I: Analysis, Part II: Results
,” ASME J. Mech. Des.
, 103
(1
), pp. 188
–194
.10.1115/1.32548605.
Zhu
, D.
, and Cheng
, H. S.
, 1991
, “A Comprehensive Analysis for Contact Geometry, Kinematics, Lubrication Performance, Bulk and Flash Temperatures in Helical Gears
,” Vehicle Tribology (Tribology Series, 18), Proceedings of the 17th Leeds-Lyon Symposium on Tribology
, Elsevier Science Publishers B.V., Amsterdam
, pp. 383
–389
.6.
Larsson
, R.
, 1997
, “Transient Non-Newtonian Elastohydrodynamic Lubrication Analysis of an Involute Spur Gear
,” Wear
, 207
(1
), pp. 67
–73
.10.1016/S0043-1648(96)07484-47.
Simon
, V.
, 1981
, “Elastohydrodynamic Lubrication of Hypoid Gears
,” ASME J. Mech. Des.
, 103
(1
), pp. 195
–203
.10.1115/1.32548638.
Chao
, H. C.
, 1982
, “A Computer Solution for the Dynamic Load, Lubricant Film Thickness, and Surface Temperatures in Spiral Bevel Gears
,” Ph.D. thesis, Northwestern University, Evanston, IL.9.
Guangteng
, G.
, and Spikes
, H. A.
, 1995
, “Behavior of Lubricants in the Mixed Elastohydrodynamic Regime
,” Lubricants and Lubrication (Tribology Series, 30), Proceedings of the 21st Leed-Lyon Symposium on Tribology
, Elsevier Science Publishers B.V., Amsterdam
, pp. 479
–485
.10.
Guangteng
, G.
, and Spikes
, H. A.
, 1997
, “The Control of Friction by Molecular Fractionation of Base Fluid Mixtures at Metal Surfaces
,” Tribol. Trans.
, 40
(3
), pp. 461
–469
.10.1080/1040200970898368111.
Luo
, J. B.
, Wen
, S. Z.
, and Huang
, P.
, 1996
, “Thin Film Lubrication. 1. Study on the Transition Between EHL and Thin Film Lubrication Using a Relative Optical Interference Intensity Technique
,” Wear
, 194
(1
), pp. 107
–115
.10.1016/0043-1648(95)06799-X12.
Guangteng
, G.
, Cann
, P. M.
, Olver
, A.
, and Spikes
, H. A.
, 2000
, “Lubricant Film Thickness in Rough Surface Mixed Elastohydrodynamic Contact
,” ASME J. Tribol.
, 122
(1
), pp. 65
–76
.10.1115/1.55533013.
Krupka
, I.
, and Hartl
, M.
, 2007
, “The Effect of Surface Texturing on Thin EHD Lubrication Films
,” Tribol. Int.
, 40
(7
), pp. 1100
–1110
.10.1016/j.triboint.2006.10.00714.
Krupka
, I.
, and Hartl
, M.
, 2007
, “The Influence of Thin Boundary Films on Real Surface Roughness in Thin Film, Mixed EHD Contact
,” Tribol. Int.
, 40
(10
), pp. 1553
–1560
.10.1016/j.triboint.2006.10.00815.
Chang
, L.
, 1995
, “A Deterministic Model for Line Contact Partial Elastohydrodynamic Lubrication
,” Tribol. Int.
, 28
(2
), pp. 75
–84
.10.1016/0301-679X(95)92697-416.
Zhu
, D.
, and Hu
, Y. Z.
, 1999
, “The Study of Transition From Full Film Elastohydrodynamic to Mixed and Boundary Lubrication
,” The Advancing Frontier of Engineering Tribology, Proceedings of the 1999 STLE/ASME H.S. Cheng Tribology Surveillance
, STLE
, Park Ridge, IL
, pp. 150
–156
.17.
Hu
, Y. Z.
, and Zhu
, D.
, 2000
, “A Full Numerical Solution to the Mixed Lubrication in Point Contacts
,” ASME J. Tribol.
, 122
(1
), pp. 1
–9
.10.1115/1.55532218.
Holmes
, M. J. A.
, Evans
, H. P.
, and Snidle
, R. W.
, 2005
, “Analysis of Mixed Lubrication Effects in Simulated Gear Tooth Contacts
,” ASME J. Tribol.
, 127
(1
), pp. 61
–69
.10.1115/1.182845219.
Zhu
, D.
, Ren
, N.
, and Wang
, Q.
, 2009
, “Pitting Life Prediction Based on a 3D Line Contact Mixed EHL Analysis and Subsurface Von Mises Stress Calculation
,” ASME J. Tribol.
, 131
(4
), p. 041501
.10.1115/1.319504020.
Zhu
, D.
, 2009
, “A Comprehensive Analysis for Mixed Elastohydrodynamic Lubrication Performance and Friction in Spur and Helical Gears
,” ASME
Paper No. IJTC2009-15148.21.
Li
, S.
, and Kahraman
, A.
, 2010
, “A Transient Mixed Elastohydrodynamic Lubrication Model for Spur Gear Pairs
,” ASME J. Tribol.
, 132
(1
), p. 011501
.10.1115/1.400027022.
Liu
, H. J.
, Mao
, K.
, Zhu
, C. C.
, Xu
, X. Y.
, and Liu
, M. Y.
, 2012
, “Parametric Studies of Spur Gear Lubrication Performance Considering Dynamic Loads
,” Proc. Inst. Mech. Eng., Part J
, 226
(9
), pp. 731
–737
.10.1177/135065011244567223.
Simon
, V.
, 2009
, “Influence of Machine Tool Setting Parameters on EHD Lubrication in Hypoid Gears
,” Mech. Mach. Theory
, 44
(5
), pp. 923
–937
.10.1016/j.mechmachtheory.2008.06.00524.
Xu
, H.
, Houser
, D. R.
, and Kahraman
, A.
, 2005
, A Model to Predict Friction Losses by Hypoid Gears
, American Gear Manufacturers Association, Alexandria, VA.
25.
Mohammadpour
, M.
, Theodossiades
, S.
, Rahnejat
, H.
, and Saunders
, T.
, 2014
, “Non-Newtonian Mixed Elastohydrodynamics of Differential Hypoid Gears at High Loads
,” Meccanica
, 49
(5
), pp. 1115
–1138
.10.1007/s11012-013-9857-x26.
Pu
, W.
, Wang
, J.
, Zhang
, Y.
, and Zhu
, D.
, 2014
, “A Theoretical Analysis of the Mixed Elastohydrodynamic Lubrication in Elliptical Contacts With an Arbitrary Entrainment Angle
,” ASME J. Tribol.
, 136
(4
), p. 041505
.10.1115/1.402812627.
Zheng
, C. Q.
, 1988
, Spiral Bevel and Hypoid Gears
, Mechanical Engineering Press
, Beijing
.28.
Litvin
, F. L.
, 1994
, Gear Geometry and Applied Theory
, Prentice-Hall
, Englewood Cliffs, NJ
.29.
Liu
, Y. C.
, Wang
, Q.
, Wang
, W. Z.
, Hu
, Y. Z.
, and Zhu
, D.
, 2006
, “Effects of Differential Scheme and Mesh Density on EHL Film Thickness in Point Contacts
,” ASME J. Tribol.
, 128
(3
), pp. 641
–653
.10.1115/1.219491630.
Zhu
, D.
, 2007
, “On Some Aspects in Numerical Solution of Thin-Film and Mixed EHL
,” Proc. Inst. Mech. Eng., Part J
, 221
(5
), pp. 561
–579
.10.1243/13506501JET25931.
Ai
, X.
, 1993
, “Numerical Analyses of Elastohydrodynamically Lubricated Line and Point Contacts With Rough Surfaces By Using Semi-System and Multigrid Methods
,” Ph.D. thesis, Northwestern University, Evanston, IL.32.
Zhu
, D.
, Liu
, Y. C.
, and Wang
, Q.
, 2014
, “On the Numerical Accuracy of Rough Surface EHL Solution
,” Tribol. Trans.
, 57
(4
), pp. 570
–580
.10.1080/10402004.2014.88634933.
Bair
, S.
, and Winer
, W. O.
, 1979
, “A Rheological Model for Elastohydrodynamic Contacts Based on Primary Laboratory Data
,” ASME J. Tribol.
, 101
(3
), pp. 258
–264
.10.1115/1.345334234.
Martini
, A.
, Zhu
, D.
, and Wang
, Q.
, 2007
, “Friction Reduction in Mixed Lubrication
,” Tribol. Lett.
, 28
(2
), pp. 171
–181
.10.1007/s11249-007-9258-135.
Zhu
, D.
, and Cheng
, H. S.
, 1989
, “An Analysis and Computational Procedure for EHL Film Thickness, Friction and Flash Temperature in Line and Point Contacts
,” Tribol. Trans.
, 32
(3
), pp. 364
–370
.10.1080/1040200890898190136.
Huang
, C.
, Zheng
, C.
, and Li
, R.
, 1992
, “An Analysis System of Loaded Tooth Contact Behavior of Spiral Gears
,” Prog. Nat. Sci.
, 2
(6
), pp. 556
–560
.Copyright © 2015 by ASME
You do not currently have access to this content.
