Prediction of Mechanical Efficiency of Parallel-Axis Gear Pairs

Abstract A computational model is proposed for the prediction of friction-related mechanical efficiency losses of parallel-axis gear pairs. The model incorporates a gear load distribution model, a friction model, and a mechanical efficiency formulation to predict the instantaneous mechanical efficiency of a gear pair under typical operating, surface, and lubrication conditions. The friction model uses a new friction coefficient formula obtained by using a validated non-Newtonian thermal elastohydrodynamic lubrication (EHL) model in conjunction with a multiple linear regression analysis. The load and friction coefficient distribution predictions are used to compute instantaneous torque/power losses and the mechanical efficiency of a gear pair at any given rotational position. Efficiency measurements from gear pairs having various gear designs and surface treatments are compared to model predictions. Mechanical efficiency predictions are shown to be within 0.1% of the measured values, indicating that the proposed efficiency model is accurate. Results of a parametric study are presented at the end to highlight the influence of key basic gear geometric parameters, tooth modifications, operating conditions, surface finish, and lubricant properties on mechanical efficiency losses.