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  • 1.
    Andersson, Martin
    et al.
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Tribologi.
    Sosa, Mario
    Sjöberg, Sören
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Tribologi.
    Olofsson, Ulf
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Tribologi.
    Effect of Assembly Errors in Back-to-Back Gear Efficiency Testing2014In: International Gear Conference 2014: 26th–28th August 2014, Lyon, Woodhead Publishing Limited, 2014, p. 784-793Conference paper (Refereed)
    Abstract [en]

    As gear efficiency is improved in small steps, it is important to be able to distinguish actual improvements from scatter that can occur while testing. An FZG back-to-back gear test rig was used to investigate how the assembly and re-assembly of the same test setup affects the measurements. A spread in loss torque between one assembly and another of the same test setup were observed. Rig conditions also affected the spread in input torque. With knowledge of how the spread in loss torque varies due to assembly, test results could be distinguished between changes due to assembly and actual differences between tests.

  • 2.
    Bergseth, Ellen
    et al.
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Elements.
    Sjöberg, Sören
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Elements.
    Björklund, Stefan
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Elements.
    Influence of real surface topography on the contact area ratio in differently manufactured spur gears2012In: Tribology International, ISSN 0301-679X, E-ISSN 1879-2464, Vol. 56, p. 72-80Article in journal (Refereed)
    Abstract [en]

    Surface topography measurements from spur gears produced using four different manufacturing methods were used as input to a contact analysis programme. All test gears were case-hardened, two gears were machined in the hardened state using honing and grinding respectively, and two gears were machined in the non-hardened state using hobbing and hobbing followed by green-shaving respectively. The results show that the surface topography caused by the manufacturing methods has a large influence on the real contact area in the early life of the gear. The green-shaved gear surfaces and the honed gear surfaces have the highest contact area ratio after manufacturing (as-manufactured), which could be advantageous for future gear life with respect to e.g. the running-in process.

  • 3.
    Sjöberg, Sören
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Elements. KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Tribologi.
    Influence of running-in on gear efficiency2014Doctoral thesis, comprehensive summary (Other academic)
    Abstract [en]

    The general trend in gear industry is an increased focus on gear transmission efficiency. This thesis focuses on the understanding of how different gear manufacturing methods – particularly the contribution of the running-in process – affect the surface characteristics and friction response, with the purpose of increasing gearbox efficiency. The thesis consists of a summary and five appended papers.

    The research hypothesis in paper A and paper B was that the dry elastic contact area ratio is a descriptive parameter for the contact condition. Paper A deals with the influence of manufacturing method on the initial contact conditions. The emphasis in paper B is the changes that occur during running-in and correlating these changes to design requirements. Paper C examines the influence of manganese phosphate coating and lubricants, with respect to friction and the risk of scuffing at the initial contact. Paper D examines the effect of running-in load on the friction response for different surfaces. In paper E, the question of whether the load during running-in influences the gear mesh efficiency is further expounded.

    The main conclusions of this thesis are that the running-in influences the gear mesh efficiency; a high running-in load enhances the gear mesh efficiency. The difference in mesh efficiency is in the range of one tenth of a per cent. Thus, the influence of running-in cannot be neglected because it is in the same order of magnitude as reported for other gear efficiency enhancements. Furthermore, the dry elastic contact area ratio presents a descriptive measure of how surface topography influences the contact, at both a global (form deviation) and local (roughness) level. The surface topography caused by the manufacturing method has a significant influence on the contact area ratio. Shaving was found to have the highest contact area ratio, and would therefore be the best choice if deviations from case hardening could be minimised. It was also confirmed that surfaces coated with manganese phosphate raise the limiting load for scuffing failure up to 13 times compared to the uncoated ground equivalent.

    Download full text (pdf)
    Thesis
  • 4.
    Sjöberg, Sören
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Elements.
    On the running-in of gears2010Licentiate thesis, comprehensive summary (Other academic)
    Abstract [en]

    The general trend in gear industry, today, is an increased focus on gear transmission efficiency. Gear transmission efficiency losses arise from loaded and unloaded gear contacts, seals, lubricant and bearings. One way of minimising the losses is to lower the lubricant viscosity. This will reduce the speed dependent losses. However, the load dependent losses might increase. To avoid this, the ratio between lubricant film thickness and surface roughness must be maintained, which can be fulfilled by producing smoother gear surfaces. As a starting point for this realisation process, the present manufacturing processes, the design tools and the characteristics of the gear flank interface must be further investigated and developed. This must be achieved with an emphasis on economic production.

    This thesis focuses on our understanding of how different gear manufacturing methods —particularly the contribution of the running-in process—affect the surface characteristics, with the view of increasing gearbox efficiency. The thesis consists of a summary and three appended papers.

    Paper A and paper B discuss the relationship between design parameters and real gear wheel surfaces manufactured with different manufacturing methods. The research hypothesis was that the contact area ratio is a descriptive parameter for the contact condition. Paper A deals with the influence of manufacturing method on the initial contact conditions and also serves as a validation of the simulation program used. The emphasis in Paper B is the changes that occur during running-in, and to correlate these changes to design requirements. Paper C approaches the influences of manganese phosphate-coating and lubricants with respect to friction and the risk of scuffing at the initial contact.

    The main conclusions of this thesis are that the contact area ratio presents a descriptive measure of how surface topography influences the contact, seen at both a global (form deviation) and local (roughness) level. The surface topography caused by the manufacturing method has a significant influence on the contact area ratio. This is an important result, since neither national standards nor commercially available gear evaluation programs handle surface topography on the local scale. Shaving was found to have the highest contact area ratio, and should therefore be the best choice if deviations from case hardening could be minimised. It is also confirmed that gear-like surfaces coated with manganese phosphate have a low coefficient of friction, and raise the limiting load for scuffing failure enormously compared to the ground equivalent.

    Download full text (pdf)
    FULLTEXT01
  • 5.
    Sjöberg, Sören
    et al.
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Tribologi. KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Design (Div.).
    Andersson, Martin
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Design (Div.). KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Tribologi.
    Olofsson, Ulf
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Design (Div.). KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Tribologi.
    Analysis of running-in using Stribeck curves, with application to gear meshManuscript (preprint) (Other academic)
  • 6.
    Sjöberg, Sören
    et al.
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Elements.
    Bergseth, Ellen
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Elements.
    Björklund, Stefan
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Elements.
    Influence of real surface topography on the contact area ratio in differently manufactured spur gears2008In: Proceedings of Tribology 2008: Surface Engineering of Automotive Powertrains for Environmentally Friendly Transport, 2008Conference paper (Refereed)
  • 7.
    Sjöberg, Sören
    et al.
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Tribologi.
    Björklund, Stefan
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Tribologi.
    Olofsson, Ulf
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Tribologi.
    The influence of manufacturing method on the running-in of gears2011In: Proceedings of the Institution of mechanical engineers. Part J, journal of engineering tribology, ISSN 1350-6501, E-ISSN 2041-305X, Vol. 225, no 10, p. 999-1012Article in journal (Refereed)
    Abstract [en]

    Striving for higher gear transmission efficiency by using a low-viscosity transmission lubricant affects the lubricant film thickness. To keep the K-ratio (the ratio between the film thickness and the surface roughness) intact, more effort must be put on the surface topography. This paper presents a study of how running-in affects the dry elastic contact area ratio in spur gears using real surface topographies from three common manufacturing methods (green-shaving, honing, and grinding). The test gears were manufactured in case-hardened steel, similar to 20MnCrS5. Surface topography measurements were used as input to a contact analysis boundary element software program. An important hypothesis used in this work is that the dry elastic contact area ratio, i.e. the ratio between real and nominal contact area, can be used as a measure of the contact conditions in gears. It is concluded that running-in differs significantly for the studied manufacturing methods and that the dry elastic contact area ratio gives a consistent description of these changes. The shaved gears have the highest dry elastic contact area ratio after running in, where the ground gears have the lowest dry elastic contact area ratio. The increase in dry elastic contact area ratio is about 30 per cent for the shaved gears, 12 per cent for the honed gears and less than 5 per cent for the ground gears. Extreme value parameters, such as R(p) and R(z), showed relatively good correlation to dry elastic contact area ratio. However no genuine correlation could be found between dry elastic contact area ratio and two-dimensional (2D) surface roughness parameters. Furthermore, traditional gear metrology form parameters do not serve as a good measure on the changes occurring during the running-in.

  • 8.
    Sjöberg, Sören
    et al.
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Elements.
    Sosa, Mario
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Elements.
    Andersson, Martin
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Elements.
    Olofsson, Ulf
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Elements.
    A study of the running-in and efficiency of ground gearsManuscript (preprint) (Other academic)
  • 9.
    Sjöberg, Sören
    et al.
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Tribologi.
    Sosa, Mario
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.).
    Andersson, Martin
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Tribologi.
    Olofsson, Ulf
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Tribologi.
    Analysis of efficiency of spur ground gears and the influence of running-in2016In: Tribology International, ISSN 0301-679X, E-ISSN 1879-2464, Vol. 93, p. 172-181Article in journal (Refereed)
    Abstract [en]

    High-performing gear transmissions are needed to reduce CO2 emissions. In this paper an FZG gear test rig was used to investigate how two running-in loads affects the gear mesh efficiency for two different temperatures. The gear surface roughness was investigated in parallel with testing. Higher efficiency was observed for tests using a high running-in load, and for low lubricant temperatures. The running-in load had a larger effect on the mesh efficiency than temperature. The high running-in load also yielded higher gear mesh efficiency and had a larger impact on surface parameters.

  • 10.
    Sjöberg, Sören
    et al.
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Elements.
    Sundh, Jon
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Elements.
    Scuffing resistance of gear surfaces: influence of manganese phosphate and lubricants2009In: Proceedings of 2nd European Conference on Tribology: ECOTRIB 2009, 2009Conference paper (Refereed)
  • 11.
    Sjöberg, Sören
    et al.
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Elements. KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Tribologi.
    Sundh, Jon
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Elements.
    Olofsson, Ulf
    KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Elements. KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Tribologi.
    Scuffing resistance of gear surfaces: influence of manganese phosphate and lubricantsManuscript (preprint) (Other academic)
1 - 11 of 11
CiteExportLink to result list
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Cite
Citation style
  • apa
  • ieee
  • modern-language-association-8th-edition
  • vancouver
  • Other style
More styles
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  • de-DE
  • en-GB
  • en-US
  • fi-FI
  • nn-NO
  • nn-NB
  • sv-SE
  • Other locale
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  • html
  • text
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