A multi-perspective method for gear efficiency and contact analysis
Rikard Hjelm, Linus Everlid, Ellen Bergseth, Florian Reinle, Boris Brodmann, Minghui Tu, Lucas Bard, Jens Wahlström
Abstract
Modern gearing applications, in particular electrification, impose new challenges in many different fields of engineering and research. In specific, new demands are imposed on gears, including higher rotational speed, lower noise acceptance, and increased efficiency, as well as increased resistance against pitting and scuffing. To meet these demands, a better understanding of gear contacts is needed. The Eurostars project Effigears proposes a novel multi-perspective methodology for assessment of gear efficiency and contact analysis. The methodology consists of using a novel surface treatment method, Triboconditioning®, implemented in a streamfinishing process, surface measurements using a scattered light method, experimental testing using the standardized FZG test rig, and contact simulations using a novel thermal elasto-hydrodynamic lubrication tool. It is found, in preliminary tests, that enhanced gear performance may be enhanced due to Triboconditioning® surface treatment. Findings also include better understanding of how surface characteristics and lubricants affect scuffing and pitting, and the effect of load distribution on gearset behavior.