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Design Problem: Develop a gear drive for a pedal-powered water craft that will be easy to manufacture, use and maintain; that will be lightweight enough for the boat to be portable; and that will eliminate the environmental risk of lubricants leaking into the water.
Surface measurement of any metal gear tooth contact surface will indicate some degree of peaks and valleys. When gears are placed in mesh, irregular contact surfaces are brought together in the typical combination of rolling and sliding motion. The surface peaks, or asperities, of one tooth randomly contact the asperities of the mating tooth. Under the right conditions, the asperities form momentary welds that are broken off as the gear tooth action continues. Increased friction and higher temperatures, plus wear debris introduced into the system are the result of this action.
Myth No. 1: Oil Is Oil. Using the wrong oil is a common cause of gear failure. Gears require lubricants blended specifically for the application. For example, slow-speed spur gears, high-speed helical gears, hypoid gears and worm gears all require different lubricants. Application parameters, such as operating speeds, transmitted loads, temperature extremes and contamination risks, must be considered when choosing an oil. Using the right oil can improve efficiency and extend gear life.
Okay, so you want to make some high quality gears for your customers, and you want to make a profit for your company, but you don't want to make a mess of the environment. What can you do?
How do we know when the gear material we buy is metallurgically correct? How can we judge material quality when all gear material looks alike?
Today gear drive operations have several options when selecting the proper lubricant for their gearboxes. As in the past, the primary lubricant used for gearbox lubrication is mineral oil. But with the advances in technology, synthetic hydrocarbons (PAOs) and polyglycols show very specific advantages in certain applications. With gear drives becoming more and more precise, it is now also to the benefit of the gear operator to verify that he or she has the proper additive package and viscosity in the lubricant selected. Fig. 1 shoes that a gear oil is a combination of a base oil and specific additives. The base oils can be either mineral oil, a synthetic or even in some cases a combination of the two.
What follows is Part 2 of a three-part article covering the principles of gear lubrication. Part 2 gives an equation for calculating the lubricant film thickness, which determines whether the gears operate in the boundary, elastohydrodynamic, or full-film lubrication regime. An equation for Blok's flash temperature, which is used for predicting the risk of scuffing, is also given.
Worm gear speed reducers give the design engineer considerable options, but these gear systems present a challenge to the lubrication engineer. Heat energy generated by the high rate of sliding and friction in the contact zone causes worm gears to be relatively inefficient compared to other gear types. Because worm gears operate under a boundary or near-boundary lubrication regime, a satisfactory lubricant should contain a friction modifier to alleviate these conditions.
Pitting and micropitting resistance of case-carburized gears depends on lubricants and lubrication conditions. Pitting is a form of fatigue damage. On this account a short time test was developed. The test procedure is described. The "pitting test" was developed as a short time test to examine the influence of lubricants on micropitting. Test results showing the influence of case-carburized gears on pitting and micropitting are presented.
This is a three-part article explaining the principles of gear lubrication. It reviews current knowledge of the field of gear tribology and is intended for both gear designers and gear operators. Part 1 classifies gear tooth failures into five modes and explains the factors that a gear designer and operator must consider to avoid gear failures. It defines the nomenclature and gives a list of references for those interested in further research. It also contains an in-depth discussion of the gear tooth failure modes that are influenced by lubrication and gives methods for preventing gear tooth failures.
Aircraft transmissions for helicopters, turboprops and geared turbofan aircraft require high reliability and provide several thousand hours of operation between overhauls. In addition, They should be lightweight and have very high efficiency to minimize operating costs for the aircraft.
This is the final part of a three-part series on the basics of gear lubrication. It covers selection of lubricant types and viscosities, the application of lubricants, and a case history
The diagnosis and prevention of gear tooth and bearing wear requires the discovery and understanding of the particular mechanism of wear, which in turn indicates the best method of prevention. Because a gearbox is a tribologically dependent mechanism, some understanding of gear and bearing tribology is essential for this process. Tribology is the general term for the study and practice of lubrication, friction and wear. If tribology is neglected or considered insignificant, poor reliability and short life will result.
Historically, wind turbine gearbox failures have plagued the industry. Yet an effective oil analysis program will increase the reliability and availability of your machinery, while minimizing maintenance costs associated with oil change-outs, labor, repairs and downtime. Practical action steps are presented here to improve reliability.
When it comes to purchasing gear lubricants, many people on both the sales and purchasing side decide to play the numbers game. The person with the most numbers, or the biggest numbers, or the lowest numbers, must have the best product - right? Wrong; gear oil selection is not a game, and numbers alone cannot determine the right product for an application.
A reader asks: While I have read a reasonable amount of the literature on the pros and cons of anti-wear and anti-scuff additives, I find that the more I read, the more confused I become. I could use some clarity in my life.
The complete product news section from the September / October 2014 Issue Gear Technology.
I must confess I sometimes find myself a bit dazed when discussing lubrication issues with either staff or vendors. The terminology seems to be all over the lot, with some terms having double meanings. Can you help cut through the confusion?
A reader asks about how to specify a method of lubrication for a speed reducer with a three-stage helical gear with a low peripheral speed.
This work establishes a baseline for aerospace spur gear behavior under oil-off conditions. The collected test results document a different oil-off time, dictated by material used.
The type of lubricant and the method of applying it to the tooth flanks of large open gears is very important from the point of view of lubrication technology and maintenance. When selecting the type of lubricant and the application method, it is important to check whether it is possible to feed the required lubricant quantity to the load-carrying tooth flanks, This is necessary to avoid deficient lubrication, damage to the gear and operational malfunctions. It is important to determine the type of lubricant, which may be fluid or grease-like. The consistency of the lubricant will have a direct impact on the ability of the lubrication system to feed adequately the lubricant to the gear. The interactions between the common types of lubricant and the lubrication application methods for open gear drives are shown in Fig. 1.
Understanding the morphology of micropitting is critical in determining the root cause of failure. Examples of micropitting in gears and rolling-element bearings are presented to illustrate morphological variations that can occur in practice.
A sampling of newsletter articles and videos related to gear manufacturing from March/April 2013.
The complete Industry News section from the March/April 2013 issue of Gear Technology.
The last decade has been a period of far-reaching change for the metal working industry. The effect of higher lubricant costs, technical advances in machine design and increasing competition are making it essential that manufacturers of gears pay more attention to testing, selecting and controlling cutting fluid systems. Lubricant costs are not a large percentage of the process cost relative to items such as raw materials, equipment and labor, and this small relative cost has tended to reduce the economic incentive to evaluate and to change cutting fluids.
Gears are currently run at high speed and under high load. It is a significant problem to develop lubricants and gears with high load-carrying capacity against scoring. The particles of molybdenum disulfide have been considered to increase the scoring resistance of the gears. The wear characteristics and the scoring resistance of the gears lubricated with MoS2 paste and MoS2 powder have been investigated. (1) However, there are few investigations on the performance of the gears coated with MoS2 film with respect to scoring.
It takes confidence to be the first to invest in new manufacturing technology. But the payback can be significant. That has been the experience at the Ford Motor Company's Transmission & Chassis Division plant at Indianapolis, IN, which boasts the world's first production application of dry hobbing.
The cutting tool is basic to gear manufacturing. Whether it's a hob, broach, shaper cutter or EDM wire, not much gets done without it. And the mission of the tool remains the same as always; removing material as quickly, accurately and cost-effectively as possible. Progress in the field tends to be evolutionary, coming gradually over time, but recently, a confluence of emerging technologies and new customer demands has caused significant changes in the machines, the materials and the coatings that make cutting tools.
I would like to comment on David Arnesen's article, "Dry Hobbing Saves Automaker Money, Improves Gear Quality," in the Nov/Dec, 1996 issue.
High-speed machining using carbide has been used for some decades for milling and turning operations. The intermittent character of the gear cutting process has delayed the use of carbide tools in gear manufacturing. Carbide was found at first to be too brittle for interrupted cutting actions. In the meantime, however, a number of different carbide grades were developed. The first successful studies in carbide hobbing of cylindrical gears were completed during the mid-80s, but still did not lead to a breakthrough in the use of carbide cutting tools for gear production. Since the carbide was quite expensive and the tool life was too short, a TiN-coated, high-speed steel hob was more economical than an uncoated carbide hob.
Sandvik presents the latest in gear milling technologies.
Question: We are contemplating purchasing a hobbing machine with dry hobbing capabilities. What do we need to know about the special system requirements for this technology?
Chicago- Results of recent studies on residual stress in gear hobbing, hobbing without lubricants and heat treating were reported by representatives of INFAC (Instrumented Factory for Gears) at an industry briefing in March of this year.
Several innovations have been introduced to the gear manufacturing industry in recent years. In the case of gear hobbing—the dry cutting technology and the ability to do it with powder-metallurgical HSS—might be two of the most impressive ones. And the technology is still moving forward. The aim of this article is to present recent developments in the field of gear hobbing in conjunction with the latest improvements regarding tool materials, process technology and process integration.
Prior to the introduction of titanium nitride to the cutting tool industry in the early 1980s, there was very little progress in the general application of hobbing in the gear cutting industry. The productivity gains realized with this new type of coating initiated a very active time of advancement in the gear manufacturing process.
For environmental and economic reasons, the use of coolant in machining processes is increasingly being questioned. Rising coolant prices and disposal costs, as well as strains on workers and the environment, have fueled the debate. The use of coolant has given rise to a highly technical system for handling coolant in the machine (cooling, filtering) and protecting the environment (filter, oil-mist collector). In this area the latest cutting materials - used with or without coolant - have great potential for making the metal-removal process more economical. The natural progression to completely dry machining has decisive advantages for hobbing.
The first part of this article, which ran in the September/October 1994 issue, explained the fundamentals of gear hobbing and some of the latest techniques, including methods of hob performance analysis and new tool configurations, being used to solve specific application problems. In this issue, the author continues his exploration of hobbing by describing the effects of progress on requirements in accuracy, as well as the latest in materials, coating and dry hobbing.
This paper will present data from both laboratory and field testing demonstrating that superfinished components exhibit lower friction, operating temperature, wear and/ or higher horsepower, all of which translate directly into increased fuel economy.
Excess lubricant supply in gearing contributes to power loss due to churning as well as the requirements of the lubrication system itself. Normally, a much larger amount of oil than required is used for cooling because so much of it is thrown away by centrifugal force. To lower the amount of lubricant required and reduce those losses, it is necessary to discover the ideal location of the supplying nozzle.
The objective of this study was to investigate the limits concerning possible reduction of lubricant quantity in gears that could be tolerated without detrimental effects on their load carrying capacity.
We talked energy efficiency with some major players in the lubricants industry— but with a focus on their products’ impact regarding energy efficiency of gears and gearboxes in wind turbines.
In the wide, wide world of moving parts, the gears required for the big jobs—the really big jobs—often experience big problems. Proper lubrication of these gears is paramount in industrial applications such as wind turbines, kilns, sugar mills, crushers, heavy construction, offshore drilling rigs, mining and quarrying.
The Integral Temperature Method for the evaluation of the scoring load capacity of gears is described. All necessary equations for the practical application are presented. The limit scoring temperature for any oil can be obtained from a gear scoring test.
Most research on micropitting is done on small-sized gears. This article examines whether those results are also applicable to larger gears.
A very direct and effective way of increasing power transmission efficiency is a changeover from mineral-oil-based lubricants to synthetic lubricants.
On gear drives running with pitch line velocities below 0.5 m/s so called slow speed wear is often observed. To solve some problems, extensive laboratory test work was started 10 years ago. A total of circ. 300,000 h running time on FZG back-to-back test rigs have been run in this speed range.
The following article is concerned with the analysis of the wear-reducing effect of PVD-coatings in gearings. Standardized test methods are used, which under near-real conditions enable statements to be made about the different forms of damage and wear (micropitting, macropitting, scuffing).
This article summarizes the use of laboratory fatigue data for bearings and gears coupled with probabilistic life prediction and EHD theories to predict the life and reliability of a commercial turboprop gearbox.
A main limiting factor in extending the use of hard coatings to machine component application is the lack of knowledge about how these inert coatings perform under lubricated conditions using today's lubricants.
In the gearing industry, gears are lubricated and cooled by various methods. At low to moderate speeds and loads, gears may be partly submerged in the lubricant which provides lubrication and cooling by splash lubrication. With splash lubrication, power loss increases considerably with speed. This is partially because of churning losses. It is shown that gear scoring and surface pitting can occur when the gear teeth are not adequately lubricated and cooled.