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In situ running-in analysis of ground gears
KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.).
KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.). System- O Komponentdesign.
KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.). System- O Komponentdesign.ORCID iD: 0000-0002-2578-9453
KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.). System- O Komponentdesign.ORCID iD: 0000-0003-2489-0688
2016 (English)In: Wear, ISSN 0043-1648, E-ISSN 1873-2577, Vol. 352-353, 122-129 p.Article in journal (Refereed) Published
Resource type
Text
Abstract [en]

The initial contact state between two interacting gears proves of interest due to empirical evidence indicating difference in life and efficiency in the long term due to the initial operation. Presented here is an analysis of the initial contact state of spur gears, made of case carburized 16MnCr5 steel, by the use of in situ surface measurements and friction measurements in a back-to-back test rig during the running-in cycles. Furthermore a method to estimate wear during running-in is proposed. Results show that the most significant changes in roughness and friction occurred during the first initial cycles at high load.

Place, publisher, year, edition, pages
Elsevier, 2016. Vol. 352-353, 122-129 p.
Keyword [en]
Gears, Running-in, Surface roughness, Friction
National Category
Materials Engineering
Identifiers
URN: urn:nbn:se:kth:diva-185340DOI: 10.1016/j.wear.2016.01.021ISI: 000372722000014Scopus ID: 2-s2.0-84960155507OAI: oai:DiVA.org:kth-185340DiVA: diva2:921546
Funder
Swedish Energy Agency
Note

QC 20160420

Available from: 2016-04-20 Created: 2016-04-18 Last updated: 2017-09-28Bibliographically approved
In thesis
1. Running-in of gears - surface and efficiency transformation
Open this publication in new window or tab >>Running-in of gears - surface and efficiency transformation
2017 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

With ever shorter development times and market demands on overall system performance such as efficiency, reliability and low maintenance, accurate predictive tools are necessary and gear drives prove to be no exception. All these characteristics have an impact on a process which has remained a riddle: running-in. Even though no consensus on a definition of this phenomena is readily available, this thesis examines efficiency, surface roughness and simulation through the optics of running-in.

Geared transmissions are known for their formidable efficiency and their extreme reliability. However, with an ever increasing power density, the ability to accurately predict mesh losses becomes of utmost importance. The accurate quantification of bearing losses as well as efficiency of ground and superfinished gears under dip lubrication are examined with respect to running-in. Results show a considerable influence on the calculation of gear mesh losses originating from which bearing loss model is chosen. Furthermore, when a larger running-in load is used on ground gears, an increase in efficiency can be observed during working operation, while for superfinished no significant changes are found. These efficiency/frictional changes are also shown to occur in the initial cycles of the running-in phase.

From a surface transformation point of view running-in is shown to be a reduction of asperity tips in case hardened ground gears, while in superfinished gears no changes were seen. These gear surface changes were measured with a novel method with a surface profilometer in-situ before, after running-in and after efficiency testing. Results also show that such changes in ground gear roughness profile occur during the very initial cycles.

In order to predict running-in, a simulation method was developed. Such method utilizes a 2D surface integral method to simulate contact between rough surfaces, but requires the use of surface hardness and an accurate lower cutoff wavelength. This cutoff wavelength proved to play a pivotal role in determining an accurate contact pressure at the proper level of granularity, hence a well defined real contact area. The predicted and measured run-in surfaces are compared and are found to be in accordance with each other.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2017. 77 p.
Series
TRITA-MMK, ISSN 1400-1179 ; 2017:12
Keyword
running-in, surface transformation, efficiency, gears, ground, superfinished
National Category
Tribology
Research subject
Machine Design
Identifiers
urn:nbn:se:kth:diva-214983 (URN)978-91-7729-520-4 (ISBN)
Public defence
2017-11-17, Gladan, Brinellvägen 83, Stockholm, 10:00 (English)
Opponent
Supervisors
Note

QC 20170928

Available from: 2017-09-28 Created: 2017-09-27 Last updated: 2017-09-28Bibliographically approved

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Sosa, MarioSellgren, UlfBjörklund, StefanOlofsson, Ulf
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