Abstract
Tooth surface wear damage is one of the main causes of gearing system failure. Excessive wear leads to tooth profile loss and an increase in transmission errors, as the worn gear surfaces are no longer conjugate. Thus, the enhancement of gear durability against wear is important for gear application. Recent works show that cutter modification can aid in reducing the tool wear in gear processing, while the wear performance of the gears produced by modified cutters is still unknown. Therefore, this study focuses on the wear performance of the gear generated by modified cutter. Numerical results show that the wear resistance can be enhanced through proper cutter modification.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Litvin F L. Gear Geometry and Applied Theory. Cambridge (UK): Cambridge University Press, 2004.
Zheng F Y, Zhang M D, Zhang W Q, Guo X D. Research on the Tooth Modification in Gear Skiving. J Mech Des140(8): 084502 (2018)
Fuentes A, Ruiz-Orzaez R, Gonzalez-Perez I. Computerized design, simulation of meshing, and finite element analysis of two types of geometry of curvilinear cylindrical gears. Comput Methods Appl Mech Eng272: 321–339 (2014)
Zheng F Y, Hua L, Han X H, Li B, Chen D F. Linkage model and manufacturing process of shaping non-circular gears. Mech Mach Theory96: 192–212 (2016)
Zheng F Y, Hua L, Han X H, Li B, Chen D F. Synthesis of shaped noncircular gear using a three-linkage computer numerical control shaping machine. J Manuf Sci Eng139(7): 071003 (2017)
Zhou Y, Wang S, Wang L, Tang J, Chen Z C. CNC milling of face gears with a novel geometric analysis. Mech Mach Theory139: 46–65 (2019)
Choy F K, Polyshchuk V, Zakrajsek J J, Handschuh R F, Townsend D P. Analysis of the effects of surface pitting and wear on the vibration of a gear transmission system. Tribol Int29(1): 77–83 (1996)
Ziaran S, Darula R. Determination of the state of wear of high contact ratio gear sets by means of spectrum and cepstrum analysis. J Vib Acoust135(2): 021008 (2013)
Zhang R L, Gu F S, Mansaf H, Wang T, Ball A D. Gear wear monitoring by modulation signal bispectrum based on motor current signal analysis. Mech Syst Signal Process94: 202–213 (2017)
Kuang J H, Lin A D. The effect of tooth wear on the vibration spectrum of a spur gear pair. J Vib Acoust123(3): 311–317 (2001)
Archard J F. Contact and rubbing of flat surfaces. J Appl Phys24(8): 981–988 (1953)
Andersson S. Partial EHD theory and initial wear of gears. Ph.D Thesis. Stockholm (Sweden): Royal Institute of Technology, 1975.
Wu S F, Cheng H S. Sliding wear calculation in spur gears. J Tribol115(3): 493–500 (1993)
Flodin A, Andersson S. Simulation of mild wear in helical gears. Wear241(2): 123–128 (2000)
Flodin A, Andersson S. A simplified model for wear prediction in helical gears. Wear249(3–4): 285–292 (2001)
Simon V. Load and stress distributions in spur and helical gears. J Mech Trans Autom Des110(2): 197–202 (1988)
Brauer J, Andersson S. Simulation of wear in gears with flank interference—A mixed FE and analytical approach. Wear254(11): 1216–1232 (2003)
Bajpai P, Kahraman A, Anderson N E. A surface wear prediction methodology for parallel-axis gear pairs. J Tribol126(3): 597–605 (2004)
Kahraman A, Bajpai P, Anderson N E. Influence of tooth profile deviations on helical gear wear. J Mech Des127(4): 656–663 (2005)
Tunalioğlu M S, Tuç B. Theoretical and experimental investigation of wear in internal gears. Wear309(1–2): 208–215 (2014)
Brandão J A, Martins R, Seabra J H O, Castro M J D. Calculation of gear tooth flank surface wear during an FZG micropitting test. Wear311(1–2): 31–39 (2014)
Masjedi M, Khonsari M M. On the prediction of steady-state wear rate in spur gears. Wear342-343: 234–243 (2015)
Henneberg M, Eriksen R L, Jørgensen B, Fich J. A quasistationary approach to particle concentration and distribution in gear oil for wear mode estimation. Wear324-325: 140–146 (2015)
Mao K. Gear tooth contact analysis and its application in the reduction of fatigue wear. Wear262(11–12): 1281–1288 (2007)
ímrek H, Düzcükoğlu H. Relation between wear and tooth width modification in spur gears. Wear262(3–4): 390–394 (2007)
Karpat F, Ekwaro-Osire S. Influence of tip relief modification on the wear of spur gears with asymmetric teeth. Tribol Trans51(5): 581–588 (2008)
Prabhu Sekar R, Sathishkumar R. Enhancement of wear resistance on normal contact ratio spur gear pairs through non-standard gears. Wear380-381: 228–239 (2017)
Prabhu Sekar R, Muthuveerappan G. A balanced maximum fillet stresses on normal contact ratio spur gears to improve the load carrying capacity through nonstandard gears. Mech Based Des Struct Mach43(2): 150–163 (2015)
Zhou C J, Xiao Z L, Chen S Y, Han X. Normal and tangential oil film stiffness of modified spur gear with non-Newtonian elastohydrodynamic lubrication. Tribol Int109: 319–327 (2017)
Shih Y P, Chen S D. Free-form flank correction in helical gear grinding using a five-axis computer numerical control gear profile grinding machine. J Manuf Sci Eng134(4): 041006 (2012)
Zheng F Y, Hua L, Han X H. The mathematical model and mechanical properties of variable center distance gears based on screw theory. Mech Mach Theory101: 116–139 (2016)
Zheng F Y, Zhang M D, Zhang W Q, Tan R L, Guo X D. On the deformed tooth contact analysis for forged bevel gear modification. Mech Mach Theory135: 192–207 (2019)
Liu X Z, Yang Y H, Zhang J. Investigation on coupling effects between surface wear and dynamics in a spur gear system. Tribol Int101: 383–394 (2016)
Bouzakis K D, Kombogiannis S, Antoniadis A, Vidakis N. Gear hobbing cutting process simulation and tool wear prediction models. J Manuf Sci Eng124(1): 42–51 (2002)
Bouzakis K D, Friderikos O, Tsiafis I. FEM-supported simulation of chip formation and flow in gear hobbing of spur and helical gears. CIRP J Manuf Sci Technol1(1): 18–26 (2008)
Claudin C, Rech J. Development of a new rapid characterization method of hob’s wear resistance in gear manufacturing—Application to the evaluation of various cutting edge preparations in high speed dry gear hobbing. J Mater Process Technol209(11): 5152–5160 (2009)
Karpuschewski B, Beutner M, Köchig M, Härtling C. Influence of the tool profile on the wear behaviour in gear hobbing. CIRP J Manuf Sci Technol18: 128–134 (2017)
Jiang J K, Fan Z D. High-order tooth flank correction for a helical gear on a six-axis CNC hob machine. Mech Mach Theory91: 227–237 (2015)
Zheng F Y, Hua L, Chen D F, Han X H. Generation of noncircular spiral bevel gears by face-milling method. J Manuf Sci Eng138(8): 081013 (2016)
Zheng F Y, Hua L, Han X H, Chen D F. Generation of noncircular bevel gears with free-form tooth profile and curvilinear tooth lengthwise. J Mech Des138(6): 064501 (2016)
Li S T. Gear contact model and loaded tooth contact analysis of a three-dimensional, thin-rimmed gear. J Mech Des124(3): 511–517 (2002)
Zhou Y, Wu Y, Wang L, Tang J, Ouyang H. A new closed-form calculation of envelope surface for modeling face gears. Mech Mach Theory137: 211–226 (2019)
Guan Y B, Fang Z D, Yang X H, Chen G D. Tooth contact analysis of crown gear coupling with misalignment. Mech Mach Theory126: 295–311 (2018)
Tran V T, Hsu R H, Tsay C B. Tooth contact analysis of double-crowned involute helical pairs shaved by a crowning mechanism with parallel shaving cutters. Mech Mach Theory79: 198–216 (2014)
Hu Z H, Ding H, Peng S D, Tang Y, Tang J Y. Numerical determination to loaded tooth contact performances in consideration of misalignment for the spiral bevel gears. Int J Mech Sci151: 343–355 (2019)
Diez-Ibarbia A, Fernandez-del-Rincon A, De-Juan A, Iglesias M, Garcia P, Viadero F. Frictional power losses on spur gears with tip reliefs. The load sharing role. Mech Mach Theory112: 240–254 (2017)
Acknowledgements
The authors would like to thank the National Natural Science Foundation of China (Nos. 51805062 and 51805060) for their support in conducting this research.
Author information
Authors and Affiliations
Corresponding author
Additional information
Fangyan ZHENG. He received his Ph.D. degree in School of Automotive Engineering, Wuhan University of Technology. His current position is an associate professor in Wuhan University of Technology. His research areas cover the gear design, gear manufacturing, geometry, mechanism, and so on.
Jun ZHANG. He received the B.S., M.S., and Ph.D. degrees from Tianjin University, China, in 2002, 2004, and 2007, respectively. He is currently the deputy director of Gear Lab, Fuzhou University, and he is also a chair professor at the School of Mechanical Engineering and Automation. He has published over 30 international journal papers and has served as a reviewer of related journals for years. His research interests include dynamic analysis, vibration control, and fault diagnosis.
Ligang YAO. He received the B.S. and M.S. degrees from Northeast Petroleum University, China in 1984 and 1987, respectively, and the Ph.D. degree from the Harbin Institute of Technology, China in 1996. He is currently a professor at the School of Mechanical Engineering and Automation of Fuzhou University, China. His research focuses on the design and manufacturing of innovative gear transmissions, rehabilitation robotics, and geometric modeling.
Rulong TAN. He received his Ph.D. degree in engineering from the State Key Laboratory of Mechanical Transmission, Chongqing University, China, in 2016. Now, he is an associate professor in Chongqing University of Technology. His research interests include bevel gear geometry, kinematics, and manufacturing.
Rights and permissions
Open Access : This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if changes were made.
The images or other third party material in this article are included in the article’s Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder.
To view a copy of this licence, visit http://creativecommons.org/licenses/by/4.0/.
About this article
Cite this article
Zheng, F., Zhang, J., Yao, L. et al. Investigation on the wear of spur gears generated by modified cutter. Friction 9, 288–300 (2021). https://doi.org/10.1007/s40544-019-0337-8
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s40544-019-0337-8