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Research Papers: Design for Manufacturing

An Experimental Study of the Influence of Manufacturing Errors on the Planetary Gear Stresses and Planet Load Sharing

[+] Author and Article Information
H. Ligata

Department of Mechanical Engineering, The Ohio State University, 201 W. 19th Avenue, Columbus, OH 43210

A. Kahraman1

Department of Mechanical Engineering, The Ohio State University, 201 W. 19th Avenue, Columbus, OH 43210kahraman.1@osu.edu

A. Singh

 Advanced Power Transfer Group, General Motors Powertrain, 30240 Oak Creek Drive, Wixom, MI 48393

1

Corresponding author.

J. Mech. Des 130(4), 041701 (Mar 19, 2008) (9 pages) doi:10.1115/1.2885194 History: Received December 28, 2006; Revised May 25, 2007; Published March 19, 2008

In this paper, results of an experimental study are presented to describe the impact of certain types of manufacturing errors on gear stresses and the individual planet loads of an n-planet planetary gear set (n=36). The experimental setup includes a specialized test apparatus to operate a planetary gear set under typical speed and load conditions and gear sets having tightly controlled intentional manufacturing errors. The instrumentation system consists of multiple strain gauges mounted on the ring gear and a multichannel data collection and analysis system. A method for computing the planet load-sharing factors from root strain-time histories is proposed. Influence of carrier pinhole position errors on gear root stresses is quantified for various error and torque values applied to gear sets having three to six planets. The results clearly indicate that manufacturing errors influence gear stresses and planet load sharing significantly. Gear sets having larger number of planets are more sensitive to manufacturing errors in terms of planet load-sharing behavior.

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Copyright © 2008 by American Society of Mechanical Engineers
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Figures

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Figure 1

A schematic showing how different types of manufacturing errors influence the position of planet tooth contact surfaces

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Figure 2

A test ring gear, a six-planet carrier assembly, and a test sun gear

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Figure 3

Four-, five- and six-planet carrier configurations used in this study

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Figure 4

(a) Cross-sectional view of the gear sets assembled in the test fixtures and (b) a view of the test fixtures on the dynamometer

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Figure 5

(a) Schematic showing strain gauge locations and (b) close-up view of a strain gauge set formed by three root gauges

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Figure 6

Variation of the measured ring gear root strains with Ts for a three-planet system having ẽc1=−70μm. (a) Ts=1000Nm, (b) Ts=800Nm, (c) Ts=600Nm, and (d) Ts=400Nm.

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Figure 7

Variation of the measured ring gear root strains with Ts for a four-planet system having ẽc1=−70μm. (a) Ts=1000Nm, (b) Ts=800Nm, (c) Ts=600Nm, and (d) Ts=400Nm.

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Figure 8

Variation of the measured ring gear root strains of a four-planet system with ẽc1 at Ts=1000Nm. (a) ẽc1=0, (b) ẽc1=−35μm, and (c) ẽc1=−70μm.

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Figure 9

Variation of the measured ring gear root strains of a four-planet system with ẽc1 at Ts=1000Nm. (a) ẽc1=0, (b) ẽc1=35μm, and (c) ẽc1=70μm.

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Figure 10

Measured variation of Lpi of a four-planet system with ẽc1. (a) Ts=600Nm, (b) Ts=800Nm, and (c) Ts=1000Nm.

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Figure 11

Variation of the measured ring gear root strains of a five-planet system with ẽc1 at Ts=1000Nm. (a) ẽc1=70μm, (b) ẽc1=0μm, and (c) ẽc1=−70μm.

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Figure 12

Measured variation of Lpi of a five-planet system with ẽc1. (a) Ts=600Nm, (b) Ts=800Nm, and (c) Ts=1000Nm.

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Figure 13

Variation of the measured ring gear root strains of a six-planet system with ẽc1 at Ts=1000Nm. (a) ẽc1=70μm, (b) ẽc1=0μm, and (c) ẽc1=−70μm.

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Figure 14

Measured variation of Lpi of a six-planet system with ẽc1. (a) Ts=600Nm, (b) Ts=800Nm, and (c) Ts=1000Nm.

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