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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.
Universal tractor transmission oil (UTTO) is multifunctional tractor oil formulated for use in transmissions, final drives, differentials, wet brakes, and hydraulic systems of farm tractors employing a common oil reservoir. In the present work, the gear protection properties of two formulated vegetable-based UTTO oils, one synthetic ester-based UTTO oil, one synthetic ester gear oil, and one mineral based UTTO oil are investigated.
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.
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.
The October 2011 issue of Gear Technology featured the article “Low-Distortion Heat Treatment of Transmission Components,” which covered the combination of low-pressure carburizing and high pressure gas quenching in an automotive environment. Here, heat treating expert Dan Herring explains why oil quenching is an appropriate choice for many applications.
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.
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.
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.
Question: Do machines exist that are capable of cutting bevel gear teeth on a gear of the following specifications: 14 teeth, 1" circular pitch, 14.5 degrees pressure angle, 4 degrees pitch cone angle, 27.5" cone distance, and an 2.5" face width?
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.
In the lubrication and cooling of gear teeth a variety of oil jet lubrication schemes is sometimes used. A method commonly used is a low pressure, low velocity oil jet directed at the ingoing mesh of the gears, as was analyzed in Reference 1. Sometimes an oil jet is directed at the outgoing mesh at low pressures. It was shown in Reference 2 that the out-of-mesh lubrication method provides a minimal impingement depth and low cooling of the gears because of the short fling-off time and fling-off angle.(3) In References 4 and 5 it was shown that a radially directed oil jet near the out-of-mesh position with the right oil pressure was the method that provided the best impingement depth.
Natural resources—minerals, coal, oil, agricultural products, etc.—are the blessings that Mother Earth confers upon the nations of the world. But it takes unnaturally large gears to extract them.
A study was performed to evaluate fault detection effectiveness as applied to gear-tooth pitting-fatigue damage. Vibration and oil-debris monitoring (ODM) data were gathered from 24 sets of spur pinion and face gears run during a previous endurance evaluation study.
Several methods of oil jet lubrication of gears are practiced by the gear industry. These include the oil jet directed into the mesh, out of the mesh and radially directed into the gear teeth. In most cases an exact analysis is not used to determine the optimum condition such as, jet nozzle location, direction and oil jet velocity, for best cooling. As a result many gear sets are operating without optimum oil jet lubrication and cooling.
Environmentally friendly cutting fluids aren't just good for the environment. They can also be good for performance.
During the last decade, industrial gear manufacturers, particularly in Europe, began to require documentation of micropitting performance before approving a gear oil for use in their equipment. The development of micropitting resistant lubricants has been limited both by a lack of understanding of the mechanism by which certain lubricant chemistry promotes micropitting and by a lack of readily available testing for evaluation of the micropitting resistance of lubricants. This paper reports results of two types of testing: (1) the use of a roller disk machine to conduct small scale laboratory studies of the effects of individual additives and combinations of additives on micropitting and (2) a helical gear test used to study micropitting performance of formulated gear oils.
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.
Industry battles it out for World's Largest Gear title.
Uncertainty casts a shadow over future business opportunities for manufacturers serving the new energy markets.
The purpose of this paper was to verify, when using an oil debris sensor, that accumulated mass predicts gear pitting damage and to identify a method to set threshold limits for damaged gears.
Editor's Note: The following article details the advantages of synthetic lubricants in certain applications. However, the user should be aware of certain design issues arising from the extract chemistry of the synthetic. For example, some synthetics may have low solvency for additives. Others may not be compatible with mineral oils or nonmetallic components such as seals and paints. Some synthetics may absorb water and may not have the same corrosion resistance as mineral oils. Finally, the user should consider biodegradability or toxicity before switching to any new lubricant. Many of these concerns are present in petroleum-based lubricants as well, so consult a lubrication specialist before specifying a lubricant.
Spur gear surface endurance tests were conducted to investigate CBN ground AISI 9310 spur gears for use in aircraft applications, to determine their endurance characteristics and to compare the results with the endurance of standard vitreous ground AISI 9310 spur gears. Tests were conducted with VIM-VAR AISI 9210 carburized and hardened gears that were finish ground with either CBN or vitreous grinding methods. Test conditions were an inlet oil temperature of 320 K (116 degree F), an outlet oil temperature of 350 K (170 degree F), a maximum Hertz stress of 1.71 GPa (248 ksi), and a speed of 10,000 rpm. The CBN ground gears exhibited a surface fatigue life that was slightly better than the vitreous ground gears. The subsurface residual stress of the CBN ground gears was approximately the same as that for the standard vitreous ground gears for the CBN grinding method used.
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.
Mineral-oil-base lubricants show a significant decrease of kinematic viscosity with rising temperature, as exemplified in Figure 1 by lubricants for vehicle gears. An important attribute of lubricants is their viscosity index (VI), according to DIN/ISO 2909 (Ref. 4). Viscosity index is a calculated coefficient, which characterizes the change of viscosity of lubricants as a function of temperature. A high viscosity index represents a low variation of viscosity due to temperature and vice versa. A low viscosity-temperature-dependence is required for lubricants that are operated at significantly varying temperature conditions, such as vehicle engine and gear lubricants in summer and winter time. This way, the oils remain flowing and pumpable at low temperatures on the one hand; and on the other hand, sufficiently thick lubricant films can be formed at higher temperatures for a safe separation of the surfaces.
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.
Precision components (industrial bearing races and automotive gears) can distort during heat treatment due to effects of free or unconstrained oil quenching. However, press quenching can be used to minimize these effects. This quenching method achieves the relatively stringent geometrical requirements stipulated by industrial manufacturing specifications. As performed on a wide variety of steel alloys, this specialized quenching technique is presented here, along with a case study showing the effects of prior thermal history on the distortion that is generated during press quenching.
Spur gear endurance tests were conducted to investigate the surface pitting fatigue life of noninvolute gears with low numbers of teeth and low contact ratios for the use in advanced application. The results were compared with those for a standard involute design with a low number of teeth. The gear pitch diameter was 8.89 cm (3.50 in.) with 12 teeth on both gear designs. Test conditions were an oil inlet temperature of 320 K (116 degrees F), a maximum Hertz stress of 1.49 GPa (216 ksi), and a speed of 10,000 rpm. The following results were obtained: The noninvolute gear had a surface pitting fatigue life approximately 1.6 times that of the standard involute gear of a similar design. The surface pitting fatigue life of the 3.43-pitch AISI 8620 noninvolute gear was approximately equal to the surface pitting fatigue life of an 8-pitch, 28-tooth AISI 9310 gear at the same load, but at a considerably higher maximum Hertz stress.
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.
What is so unique about gear manufacturing and inspection? Machining is mostly associated with making either flat or cylindrical shapes. These shapes can be created by a machine's simple linear or circular movements, but an involute curve is neither a straight line nor a circle. In fact, each point of the involute curve has a different radius and center of curvature. Is it necessary to go beyond simple circular and linear machine movements in order to create an involute curve? One of the unique features of the involute is the fact that it can be generated by linking circular and linear movements. This uniqueness has become fertile soil for many inventions that have simplified gear manufacturing and inspection. As is the case with gear generating machines, the traditional involute inspection machines take advantage of some of the involute properties. Even today, when computers can synchronize axes for creating any curve, taking advantage of involute properties can be very helpful. I t can simplify synchronization of machine movements and reduce the number of variables to monitor.
Nondestructive examination (NDE) of ferrous and nonferrous materials has long proved an effective maintenance and anomaly characterization tool for many industries. Recent research has expanded its applicability to include the inspection of large, open gear drives. Difficulties inherent in other NDE methods make them time-consuming and labor-intensive. They also present the user with the environmental problem of the disposal of used oil. The eddy current method addresses these problems.
By increasing the number of gears and the transmission-ratio spread, the engine will run with better fuel efficiency and without loss of driving dynamics. Transmission efficiency itself can be improved by: using fuelefficient transmission oil; optimizing the lubrication systems and pumps; improving shifting strategies and optimizing gearings; and optimizing bearings and seals/gaskets.
The first edition of the international calculation method for micropitting—ISO TR 15144–1:2010—was just published last December. It is the first and only official, international calculation method established for dealing with micropitting. Years ago, AGMA published a method for the calculation of oil film thickness containing some comments about micropitting, and the German FVA published a calculation method based on intensive research results. The FVA and the AGMA methods are close to the ISO TR, but the calculation of micropitting safety factors is new.
There are great advantages in dry hobbing, not only for friendliness toward the environment, but also for increasing productivity and for decreasing manufacturing cost. Dry hobbing, however, often causes failures in hob cutting edges or problems with the surface quality of gear tooth flanks. These difficulties are not present when hobbing with cutting oil. Pinching and crushing of generated chips between the hob cutting edge and the work gear tooth flank is considered a major cause of those problems.
The world economy is in turmoil. A year ago, the Dow Jones industrial average was more than 14,000. As I write this, after eight straight days of massive losses and a week of wild up-and-down swings, the average sits at about 8,900.
Part I, which was published in the September/October 2008 issue, covered gear materials, desired microstructure, coil design and tooth-by-tooth induction hardening. Part II covers spin hardening and various heating concepts used with it.
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.
Long before oil, climate change and energy demand were making headlines in Washington, Minnesota State Auditor Rebecca Otto and her husband installed a wind energy system on their property in Minnesota.
Induction hardening is a heat treating technique that can be used to selectively harden portions of a gear, such as the flanks, roots and tips of teeth, providing improved hardness, wear resistance, and contact fatigue strength without affecting the metallurgy of the core and other parts of the component that don’t require change. This article provides an overview of the process and special considerations for heat treating gears. Part I covers gear materials, desired microsctructure, coil design and tooth-by-tooth induction hardening.
An offshore jack-up drilling rig is a barge upon which a drilling platform is placed. The barge has legs that can be lowered to the sea floor to support the rig. Then the barge can be “jacked up” out of the water, providing a stable work platform from which to drill for oil and gas. Jack-up drilling rigs were first introduced in the late 1950s. Rack-and- pinion-type jack-up units were introduced soon after that and have dominated the industry ever since.
This paper shows an experimental study on the fatigue lifetime of high-heat polyamide (Stanyl) gears running in oil at 140°C. Based on previous works (Refs. 1–2), an analysis is made correcting for tooth bending and calculating actual root stresses. A comparison with tensile bar fatigue data for the same materials at 140°C shows that a good correlation exists between gear fatigue data and tensile bar fatigue data. This insight provides a solid basis for gear designers to design plastic gears using actual material data.
In this paper, a method is presented for analyzing and documenting the pitting failure of spur and helical gears through digital photography and automatic computerized evaluation of the damaged tooth fl ank surface. The authors have developed an accurate, cost-effective testing procedure that provides an alternative to vibration analysis or oil debris methods commonly used in conjunction with similar test-rig programs.
A very direct and effective way of increasing power transmission efficiency is a changeover from mineral-oil-based lubricants to synthetic lubricants.
News Items About oil
1 Fluorescent Dye Pinpoints Oil Leaks (September 1, 2010)
Dye-Lite TP-3100 fluorescent dye pinpoints engine oil, hydraulic fluid, lubrication fluid, compressor oil and gearbox oil leaks. Simply a... Read News
2 Ikona Launches Six New Gearing Products for Oil and Gas Exploration (April 19, 2006)
Ikona Industries launched six new gearing products for the oil and gas industry at The Global Petroleum Show in June. ?Our oil and ga... Read News
3 Vectron’s Viscosity Sensor Detects Oil Change in Gearbox (May 29, 2007)
The low shear ViSmart™ viscosity sensor from Vectron International was recently used to collect real-time viscosity data in an oil-aging ... Read News
4 Ikona Gear Launches Oil and Gas Division, Signs Licensing Agreements (March 9, 2006)
Ikona Gear launched Ikona Industries Corp. to focus on developing, manufacturing and shipping novel gearing applications for the oil and ... Read News
5 New Industrial Gear Oil Enhances Gearbox Durability (January 15, 2006)
The new Mobilgear 600 XP Series of premium industrial gear oils was introdu... Read News
6 Inductoheat Expands Coil Department (March 16, 2005)
Inductoheat has expanded its inductor coil build and repair department and now operates a state-of-the-art machine shop in tandem with it... Read News
7 ExxonMobils New Industrial Gear Oils Surpasses Demanding Industry Specifications (January 14, 2006)
ExxonMobils new Mobilgear 600XP Series of premium industrial gear oils has been announced worldwide. Its balanced formulation a... Read News
8 25 Bar Furnace Acts as Alternative to Oil Quench (November 9, 2009)
Seco/Warwick introduced a 25 Bar Single Chamber Vacuum Furnace as a process alternative to vacuum furnaces using an oil quench. The 25 B... Read News
9 Pico's New Technology Cutting Oil Replaces Chlorinated Paraffin-Based Fluids (August 8, 2007)
Pico Chemical Corp. announced a chlorine-free and blue cutting oil for hard-to-machine stainless and titanium alloys. The... Read News
10 Forest City Gear Celebrates 55 Years with Corn Boil (September 1, 2010)
Forest City Gear celebrated its 55th year in business with a good old-fashioned corn boil on the company premises, July 24, 2010. O... Read News
11 Seco to Offer Oil and Gas Solutions at Houstex (December 11, 2012)
At Houstex 2013 in booth 1323, Seco Tools will showcase its oil and gas machining applications expertise, as well as its advanced tooling... Read News
12 Mazak to Showcase Oil and Gas Production Innovations (December 11, 2013)
Mazak invites oil and gas and other large part manufacturers to its Discover More With Mazak event that’s taking place Jan. 15 and ... Read News
13 Oelheld Develops HSS Grinding Oil (January 24, 2014)
SintoGrind HSS was especially developed for profile and flute grinding of steel alloys and in particular for High-Speed-Steel and medical... Read News
14 New Oil from Heatbath Corp. (February 2, 2005)
Lab Oil 100 from Heatbath Corp. is dry-to-the-touch over phosphate coating, low in toxicity, has improved emulsification and high corrosi... Read News
15 GE Oil and Gas to Acquire Allen Gears (December 12, 2013)
Expanding its presence in the industrial gears sector, GE Oil & Gas, recently announced it has signed an agreement to acquire Allen G... Read News
16 Royal Purple Develops High Performance Worm Gear Oils (May 1, 2006)
Royal Purple developed a para-synthetic Synergy Worm Gear Oil and a fully synthetic Thermyl-Glyde Worm Gear Oil. Both contain slippery... Read News
17 Seco to Spotlight Latest Tools for Oil and Gas Applications at HOUSTEX (December 15, 2014)
At HOUSTEX 2015 in booth 441, Seco Tools, LLC will highlight its latest threading, milling and turning cutting tools made to handle the m... Read News
18 Honing Oil Offers Extended Service (June 2, 2010)
Sunnen meets contemporary needs for planet friendly industrial consumables with the introduction of SHO-500, a long-lived general-purpose... Read News
19 Oil-Rites Redesigns Broad View Level Gage (March 28, 2007)
Oil-Rite Corp. re-designed its broad view level gage to reduce the number of unique components. Liquid level gages are used in various... Read News
20 Philadelphia Gear Offers Two Versions of Continuous Oil Rescue Equipment (March 5, 2007)
Philadelphia Gear Corp. announced the availability of two versions of the company's proprietary CORE Continuous Oil Rescue Equipment.... Read News
21 Coating Technology Extends Tool Life without Cutting Oil (April 2, 2009)
Mitsubishi Heavy Industries, Ltd. has developed a thin-film coating for applying to precision cutting tool surfaces to extend tool life a... Read News