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A study of the efficiency of spur gears made of powder metallurgy materials - ground versus super-finished surfaces
KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.).
KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.).
KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.).
KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.).ORCID iD: 0000-0003-2489-0688
2016 (English)In: Tribology International, ISSN 0301-679X, E-ISSN 1879-2464, Vol. 95, no 1, 211-220 p.Article in journal (Refereed) Published
Abstract [en]

Power loss is one of the main concerns in gear transmission systems. In this study a recirculating power back-to-back FZG test rig was used to investigate the efficiency of spur gears made of powder metallurgy (PM) material using two different surface manufacturing methods (ground and super-finished). The results were compared with previously presented results of standard gear material from the same test rig. The influence of the material (Wrought steel or PM) and surface roughness on the gear mesh efficiency and the total efficiency of the gearbox were analyzed in detail. The Young's modulus for PM materials is lower than for conventional gear steel. This may influence gear tooth bending and the efficiency of the gear transmission. Gear contact simulation results showed that the influence of gear tooth bending on PM gear transmission efficiency can be ignored in the FZG gear geometry. Higher surface energy combined with a smoother surface led to a lower transmission efficiency for the super-finished powder metallurgy gear combination compared to the standard gear material.

Place, publisher, year, edition, pages
Elsevier, 2016. Vol. 95, no 1, 211-220 p.
National Category
Mechanical Engineering
Identifiers
URN: urn:nbn:se:kth:diva-179702DOI: 10.1016/j.triboint.2015.11.021ISI: 000371103400024Scopus ID: 2-s2.0-84949433501OAI: oai:DiVA.org:kth-179702DiVA: diva2:885917
Note

QC 20160121

Available from: 2015-12-21 Created: 2015-12-21 Last updated: 2017-12-01Bibliographically approved
In thesis
1. Efficiency and wear properties of spur gears made of powder metallurgy materials
Open this publication in new window or tab >>Efficiency and wear properties of spur gears made of powder metallurgy materials
2016 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Powder metallurgy (PM) is usually used in manufacturing parts with complex geometries, such as gears and structural parts. The main attractions of PM are the high rate of material utilization, environmental friendliness of production, economic advantages (especially for complex geometries), and possibility of obtaining lighter components. To find a wide range of applications and compete with regular steel gears, PM gear transmissions should have good transmission efficiency and wear properties. Furthermore, they should have low contact noise and adequate surface fatigue properties. Because of the porosity structure of PM gears both on gear flanks and in the body, the friction and wear properties of PM gear flank contacts differ somewhat from those of regular steel gears.

   This doctoral thesis examines the efficiency and wear properties of PM gears. Paper A compares the wear, friction, and damage mechanism properties of two sintered gear materials with those of a standard gear material. Paper B deals with the gear mesh torque loss mechanism of PM and regular steel gears by combining both pin-on-disc frictional and FZG efficiency tests. Paper C comparatively examines the efficiency of PM and regular steel gears by conducting FZG gear efficiency tests. Paper D focuses on the wear and friction properties of PM and regular steel gear materials treated using the triboconditioning process. Paper E studies the friction and wear properties attributable to different pore sizes in PM gear materials.

   The results indicate that regular steel meshed with PM gear material and PM meshed with PM gear material are good candidate combinations for gear transmissions. This is because the porosities of PM material can lower the friction coefficient while the wear rate can be the same as or even better than that of regular steel contacts. The triboconditioning process enhances the wear resistance and reduces the friction coefficient of the PM gear material. The friction and wear coefficients of PM meshed with PM gear material display increasing trends with increasing pore size. The friction and wear coefficients of regular steel meshed with PM gear material display decreasing trends with increasing pore size.

Place, publisher, year, edition, pages
KTH Royal Institute of Technology, 2016. 125 p.
Series
TRITA-MMK, ISSN 1400-1179 ; 2016:04
Keyword
Powder Metallurgy Gears; Efficiency; Wear; Friction; Porosity Structure; FZG gear test rig
National Category
Tribology
Research subject
Machine Design
Identifiers
urn:nbn:se:kth:diva-187446 (URN)978-91-7595-963-4 (ISBN)
Public defence
2016-06-03, Galanta, Brinellvägen 83, Stockholm, 10:00 (English)
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Supervisors
Note

QC 20160523

Available from: 2016-05-23 Created: 2016-05-23 Last updated: 2016-05-23Bibliographically approved

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Olofsson, Ulf

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