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Research Papers: Power Transmissions and Gearing

An Experimental Investigation of Spur Gear Efficiency

[+] Author and Article Information
T. T. Petry-Johnson, D. R. Chase

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

A. Kahraman1

Department of Mechanical Engineering,  The Ohio State University, Columbus, OH 43210kahraman.1@osu.edu

N. E. Anderson

Advanced Power Transfer Group,  General Motors Powertrain, Wixom, MI 48393

1

Corresponding author.

J. Mech. Des 130(6), 062601 (Apr 14, 2008) (10 pages) doi:10.1115/1.2898876 History: Received March 27, 2007; Revised July 25, 2007; Published April 14, 2008

In this study, a test methodology was developed for the measurement of spur gear efficiency under high-speed and variable torque conditions. A power-circulating test machine was designed to operate at speeds to 10,000rpm and transmitted power levels to 700kW. A precision torque measurement system was implemented, and its accuracy and repeatability in measuring torque loss in the power loop was demonstrated. Tests were conducted on gears with two values of modules and two surface roughness levels, operating in a dry sump jet-lubrication environment with three different gear lubricants. These tests were used to quantify the influence of these parameters on both load-dependent (mechanical), load-independent (spin), and total power loss. Trends in mechanical gear mesh efficiency and total gearbox efficiency were discussed in terms of rotational speed and transmitted torque. Finally, recommendations were made for the design of spur gear pairs, surface roughness, and lubricant selection for improved efficiency.

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Copyright © 2008 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

(a) The spur gear efficiency test machine and (b) a schematic layout of the machine

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Figure 2

Examples of test gears: a 23T gear and a 40T gear

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Figure 3

Viscosity-temperature characteristic for the lubricants used in this study. Other mechanical properties are listed in Table 3.

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Figure 4

Comparison of repeatability tests using 40T chemically polished gears in lubricant A (19.5mm face width)

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Figure 5

Comparison of measured Pm for 23T and 40T ground gear pairs as a function of (a) Ω at Tc=413Nm and (b) Tc at Ω=6000rpm

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Figure 6

Measured η¯m values of 23T and 40T ground gear pairs in lubricant A at test conditions listed in Table 4

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Figure 7

Influence of m on measured Pm for 23T and 40T gear pairs. (a1) Ground gears in lubricant A, (a2) chemically polished gears in lubricant A, (b1) ground gears in lubricant B, (b2) chemically polished gears in lubricant B, (c1) ground gears in lubricant C, and (c2) chemically polished gears in lubricant C

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Figure 8

Influence of chemical polishing on measured Pm for (a1) 23T gears in lubricant A, (a2) 40T gears in lubricant A, (b1) 23T gears in lubricant B, (b2) 40T gears in lubricant B, (c1) 23T gears in lubricant C, and (c2) 40T gears in lubricant C

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Figure 9

Influence of m, chemical polishing, and lubricant type on measured η¯m for 23T and 40T gears in lubricants A, B, and C

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Figure 10

Comparison of measured Pspin of 23T and 40T gear pairs in lubricants A, B, and C as a function of Ω. (a) 23T ground gear pairs and (b) 40T ground gear pairs.

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Figure 11

Components of measured PT for 40T ground gear pairs in lubricant A as a function of Ω. (a) Tc=413Nm, (b) Tc=546Nm, and (c) Tc=684Nm.

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Figure 12

Measured η¯T values of 23T and 40T ground gear pairs in lubricant A at various test conditions listed in Table 4

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Figure 13

Comparison of average measured η¯T for 23T and 40T ground and chemically polished gear pairs in lubricants A, B, and C

Tables

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