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 and transmitted power levels to . 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.
Issue Section:
Power Transmissions and Gearing
1.
Denny
, C. M.
, 1998, “Mesh Friction in Gearing
,” AGMA Fall Technical Meeting
, Paper No. 98FTM2.2.
Pedrero
, J. I.
, 1999, “Determination of the Efficiency of Cylindrical Gear Sets
,” Fourth World Congress on Gearing and Power Transmission
, Paris, France
.3.
Michlin
, Y.
, and Myunster
, V.
, 2002, “Determination of Power Losses in Gear Transmissions With Rolling and Sliding Friction Incorporated
,” Mech. Mach. Theory
0094-114X, 37
, pp. 167
–174
.4.
Höhn
, B.-R.
, Michaelis
, K.
, and Wimmer
, A.
, 2005, “Low Loss Gears
,” AGMA Fall Technical Meeting
, Paper No. 05FTM11.5.
Anderson
, N. E.
, and Loewenthal
, S. H.
, 1981, “Effect of Geometry and Operating Conditions on Spur Gear System Power Loss
,” ASME J. Mech. Des.
0161-8458, 103
, pp. 151
–159
.6.
Anderson
, N. E.
, and Loewenthal
, S. H.
, 1982, “Design of Spur Gears for Improved Efficiency
,” ASME J. Mech. Des.
0161-8458, 104
, pp. 767
–774
.7.
Anderson
, N. E.
, and Loewenthal
, S. H.
, 1986, “Efficiency of Nonstandard and High Contact Ratio Involute Spur Gears
,” ASME J. Mech., Transm., Autom. Des.
0738-0666, 108
, pp. 119
–126
.8.
Vaishya
, M.
, and Houser
, D. R.
, 1999, “Modeling and Measurement of Sliding Friction for Gear Analysis
,” AGMA Fall Technical Meeting
, Lakewood, CO
, Paper No. 99FTMS1.9.
Heingartner
, P.
, and Mba
, D.
, 2003, “Determining Power Losses in The Helical Gear Mesh: Case Study
,” Proceedings of DETC’3, ASME 2003 Design Engineering Technical Conferences and Computers and Information in Engineering Conference
, Chicago, IL
.10.
Diab
, Y.
, Ville
, F.
, Velex
, P.
, 2006, “Prediction of Power Losses Due to Tooth Friction in Gears
,” Tribol. Trans.
1040-2004, 39
(2
), pp. 260
–270
.11.
Dowson
, D.
, and Higginson
, G. R.
, 1964, “A Theory of Involute Gear Lubrication
,” Proceedings of a Symposium Organized by the Mechanical Tests of Lubricants Panel of the Institute
, Institute of Petroleum, Gear Lubrication, Elsevier, London
, pp. 8
–15
.12.
Martin
, K. F.
, 1981, “The Efficiency of Involute Spur Gears
,” ASME J. Mech. Des.
0161-8458, 103
, pp. 160
–169
.13.
Simon
, V.
, 1981, “Load Capacity and Efficiency of Spur Gears in Regard to Thermo-End Lubrication
,” International Symposium on Gearing and Power Transmissions
, Tokyo, Japan
.14.
Wu
, S.
, and Cheng
, H. S.
, 1991, “A Friction Model of Partial-EHL Contacts and its Application to Power Loss in Spur Gears
,” Tribol. Trans.
1040-2004, 34
, pp. 398
–407
.15.
Mihalidis
, A.
, Bakolas
, V.
, Panagiotidis
, K.
, and Drivakos
, N.
, 2002, “Prediction of The Friction Coefficient of Spur Gear Pairs
,” VDI-Ber.
0083-5560, 1665
, pp. 705
–719
.16.
Xu
, H.
, Kahraman
, A.
, Anderson
, N. E.
, and Maddock
, D. G.
, 2007, “Prediction of Mechanical Efficiency of Parallel-Axis Gear Pairs
,” ASME J. Mech. Des.
1050-0472, 129
, pp. 58
–68
.17.
Naruse
, C.
, Haizuka
, S.
, Nemoto
, R.
, and Kurokawa
, K.
, 1986, “Studies on Frictional Loss, Temperature Rise and Limiting Load for Scoring of Spur Gear
,” Bull. JSME
0021-3764, 29
, pp. 600
–608
.18.
Naruse
, C.
, Nemoto
, R.
, Haizuka
, S.
, and Takahashi
, H.
, 1991, “Influences of Tooth Profile in Frictional Loss and Scoring Strength in the Case of Spur Gears
,” JSME International Conference on Motion and Power Transmissions
, Hiroshima, Japan
, pp. 1078
–1083
.19.
Yoshizaki
, M.
, Naruse
, C.
, and Haizuka
, S.
, 1991, “Study on Frictional Loss of Spur Gears (Concerning the Influence of Tooth Form, Load, Tooth Surface Roughness, and Lubricating Oil)
,” Tribol. Trans.
1040-2004, 34
, pp. 138
–146
.20.
Ikejo
, K.
, and Nagamura
, K.
, 2003, “Power Loss of Spur Gear Drive Lubricated With Traction Oil
,” Proceedings of DETC’3, ASME 2003 Design Engineering Technical Conferences and Computers and Information in Engineering Conference
, Chicago, IL
.21.
Coy
, J.
, Mitchell
, A.
, and Hamrock
, B.
, 1984, “Transmission Efficiency Measurements and Correlations With Physical Characteristics of the Lubricant
,” NASA, Report No. TM ADA149179.22.
Martins
, R.
, Seabra
, J.
, Brito
, A.
, Seyfert
, C.
, Luther
, R.
, and Igartua
, A.
, 2006, “Friction Coefficient in FZG Gears Lubricated With Industrial Gear Oils: Biodegradable Ester Vs. Mineral Oil
,” Tribol. Int.
0301-679X, 39
, pp. 512
–521
.23.
Xiao
, L.
, Amini
, N.
, and Rosen
, B.-G.
, 2001, “An Experimental Study on the Effect of Surface Topography on Rough Friction in Gears
,” JSME International Conference on Motion and Power Transmission
, Fukuoka, Japan
, Nov. 15–17, pp. 547
–552
.24.
Britton
, R. D.
, Elcoate
, C. D.
, Alanou
, M. P.
, Evans
, H. P.
, and Snidle
, R. W.
, 2000, “Effect of Surface Finish on Gear Tooth Friction
,” Trans. ASME, J. Tribol.
0742-4787, 122
, pp. 354
–360
.25.
Dawson
, P. H.
, 1984, “Windage Losses in Larger High-Speed Gears
,” Proc. Inst. Mech. Eng., Part A
0957-6509, 198
(1
), pp. 51
–59
.26.
Diab
, Y.
, Ville
, F.
, Velex
, P.
, and Changenet
, C.
, 2004, “Windage Losses in High Speed Gears: Preliminary Experimental and Theoretical Results
,” ASME J. Mech. Des.
1050-0472, 126
, pp. 903
–908
.27.
Ariura
, Y.
, Ueno
, T.
, and Sunaga
, T.
, 1973, “The Lubricant Churning Loss in Spur Gear Systems
,” Bull. JSME
0021-3764, 16
, pp. 881
–890
.28.
Mizutani
, H.
, 1999, “Power Loss of Long Addendum Spur Gears With Large Chamfer on Tooth Tip-Ends
,” Fourth World Congress on Gearing and Power Transmission
, Paris, France
.29.
Akin
, L. S.
, and Mross
, J. J.
, 1960, “Chamber Dimension Effects of Induced Flow and Frictional Resistance of Enclosed Rotating Disks
,” ASME J. Basic Eng.
0021-9223, 82
, pp. 217
–232
.30.
Perchersky
, M. J.
, and Wittbrodt
, M. J.
, 1987, “An Analysis of Fluid Flow Between Meshing Spur Gear Teeth
,” MS thesis, Pennsylvania State University, State College, PA.31.
Diab
, Y.
, Ville
, F.
, Houjoh
, H.
, Sainsot
, P.
, and Velex
, P.
, 2005, “Experimental and Numerical Investigations on the Air-Pumping Phenomenon in High-Speed Spur and Helical Gears
,” Proc. Inst. Mech. Eng., Part C: J. Mech. Eng. Sci.
0954-4062, 219
, pp. 785
–800
.32.
Daily
, J.
, and Nece
, R.
, 1960, “Chamber Dimension Effects of Induced Flow and Frictional Resistance of Enclosed Rotating Disks
,” ASME J. Basic Eng.
0021-9223, 82
, pp. 217
–232
.33.
Mann
, R.
, and Martson
, C.
, 1961, “Friction Drag on Bladed Disks in Housings as a Function of Reynolds Number, Axial and Radial Clearance, and Blade Aspect Ratio and Solidity
,” ASME J. Basic Eng.
0021-9223, 83
, pp. 719
–723
.34.
Boness
, R. J.
, 1989, “Churning Losses of Discs and Gear Running Partially Submerged in Oil
,” Proceedings of the ASME International Power Transmission and Gearing Conference
, Chicago
, Vol. 1
, pp. 355
–359
.35.
Terekhov
, A. S.
, 1991, “Basic Problems of Heat Calculation of Gear Reducers
,” JSME International Conference on Motion and Power Transmissions
, Hiroshima, Japan
, pp. 490
–495
.36.
Höhn
, B.-R.
, Michaelis
, K.
, and Vollmer
, T.
, 1996, “Thermal Rating of Gear Drives: Balance Between Power Loss and Heat Dissipation
,” AGMA Fall Technical Meeting
, Paper No. 96FTM8.37.
Luke
, P.
, and Olver
, A. V.
, 1999, “A Study of Churning Losses in Dip-Lubricated Spur Gears
,” Proc. Inst. Mech. Eng., Part A
0957-6509, 213
, pp. 337
–346
.38.
Changenet
, C.
, and Velex
, P.
, 2007, “A Model for the Prediction of Churning Losses in Geared Transmissions-Preliminary Results
,” ASME J. Mech. Des.
1050-0472, 129
, pp. 128
–133
.39.
Khonsari
, M. M.
, and Booser
, E. R.
, 2001, Applied Tribology, Bearing Design and Lubrication
, Wiley
, New York
.40.
ISO
Technical Report No. 14179-1:2001(E).41.
Chase
, D.
, 2005, “The Development of an Efficiency Test Methodology for High-Speed Gearboxes
,” MS thesis, The Ohio State University, Columbus, OH.Copyright © 2008
by American Society of Mechanical Engineers
You do not currently have access to this content.
