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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.
This paper addresses the lubrication of helical gears - especially those factors influencing lubricant film thickness and pressure. Contact between gear teeth is protected by the elastohydrodynamic lubrication (EHL) mechanism that occurs between nonconforming contact when pressure is high enough to cause large increases in lubricant viscosity due to the pressure-viscosity effect, and changes of component shape due to elastic deflection. Acting together, these effects lead to oil films that are stiff enough to separate the contacting surfaces and thus prevent significant metal-to-metal contact occurring in a well-designed gear pair.
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.
Tooth contact under load is an important verification of the real contact conditions of a gear pair and an important add-on to the strength calculation according to standards such as ISO, AGMA or DIN. The contact analysis simulates the meshing of the two flanks over the complete meshing cycle and is therefore able to consider individual modifications on the flank at each meshing position.
This article is part four of an eight-part series on the tribology aspects of angular gear drives. Each article will be presented first and exclusively by Gear Technology, but the entire series will be included in Dr. Stadtfeldâ€™s upcoming book on the subject, which is scheduled for release in 2011.
In the majority of spiral bevel gears, spherical crowning is used. The contact pattern is set to the center of the active tooth flank and the extent of the crowning is determined by experience. Feedback from service, as well as from full-torque bench tests of complete gear drives, has shown that this conventional design practice leads to loaded contact patterns, which are rarely optimal in location and extent. Oversized reliefs lead to small contact area, increased stresses and noise, whereas undersized reliefs result in an overly sensitive tooth contact.
This article describes some of the most important tests for prototypes conducted at Winergy AG during the product development process. It will demonstrate that the measurement results on the test rig for load distribution are in accordance with the turbine measurements.
We need a method to analyze cumulative fatigue damage to specify and to design gear drives which will operate under varying load. Since load is seldom constant, most applications need this analysis.
An analytical method is presented to predict the shifts of the contact ellipses on spiral bevel gear teeth under load. The contact ellipse shift is the motion of the point to its location under load. The shifts are due to the elastic motions of the gear and pinion supporting shafts and bearings. The calculations include the elastic deflections of the gear shafts and the deflections of the four shaft bearings. The method assumes that the surface curvature of each tooth is constant near the unloaded pitch point. Results from these calculations will help designers reduce transmission weight without seriously reducing transmission performance.
The complete and accurate solution t the contact problem of three-dimensional gears has been, for the past several decades, one of the more sought after, albeit elusive goals in the engineering community. Even the arrival on the scene in the mid-seventies of finite element techniques failed to produce the solution to any but the most simple gear contact problems.
Analysis of helical involute gears by tooth contact analysis shows that such gears are very sensitive to angular misalignment leading to edge contact and the potential for high vibration. A new topology of tooth surfaces of helical gears that enables a favorable bearing contact and a reduced level of vibration is described. Methods for grinding helical gears with the new topology are proposed. A TCA program simulating the meshing and contact of helical gears with the new topology has been developed. Numerical examples that illustrate the proposed ideas are discussed.
Photography is an essential part of gear failure analysis. It not only provides a fast, convenient way to accurately document the appearance of gear failure, but also is an effective diagnostic tool because the magnification obtained through photographic enlargement and slide projection often discloses evidence that may have been missed if the gears were not photographed.
Recent advances in spiral bevel gear geometry and finite element technology make it practical to conduct a structural analysis and analytically roll the gear set through mesh. With the advent of user-specific programming linked to 3-D solid modelers and mesh generators, model generation has become greatly automated. Contact algorithms available in general purpose finite element codes eliminate the need for the use and alignment of gap elements. Once the gear set it placed in mesh, user subroutines attached to the FE code easily roll it through mesh. The method is described in detail. Preliminary result for a gear set segment showing the progression of the contact line load is given as the gears roll through mesh.
The present article contains a preliminary description of studies carried out by the authors with a view toward developing asymmetrical gear teeth. Then a comparison between numerous symmetrical and asymmetrical tooth stress fields under the same modular conditions follows. This leads to the formulation of a rule for similar modules governing variations of stress fields, depending on the pressure angle of the nonactive side. Finally a procedure allowing for calculations for percentage reductions of asymmetrical tooth modules with respect to corresponding symmetrical teeth, maximum ideal stress being equal, is proposed. Then the consequent reductions in size and weight of asymmetrical teeth are assessed.
This article illustrates a structural analysis of asymmetrical teeth. This study was carried out because of the impossibility of applying traditional calculations to procedures involved in the specific case. In particular, software for the automatic generation of meshes was devised because existing software does not produce results suitable for the new geometrical model required. Having carried out the structural calculations, a comparative study of the stress fields of symmetrical and asymmetrical teeth was carried out. The structural advantages of the latter type of teeth emerged.
Would you like to be able to see the condition of the gears in your transmissions without having to open the box and physically examine them? There is a way, and not too many people know about it. It's called Wear Particle Analysis, or ferrography, and it is just starting to get noticed.
"Gear Train" is a new Gear Technology section focusing on training and education in the gear industry. For the first installment, we've focused on AGMA's online and video training programs.
How does one perform a contact analysis for worn gears? Our expert responds.
This paper will provide examples of stress levels from conventional root design using a hob and stress levels using an optimized root design that is now possible with PM manufacturing. The paper will also investigate how PM can reduce stresses in the root from transient loads generated by abusive driving.
Gear-loaded tooth contact analysis is an important tool for the design and analysis of gear performance within transmission and driveline systems. Methods for the calculation of tooth contact conditions have been discussed in the literature for many years. It's possible the method you've been using is underestimating transmission error in helical gears. Here's why.
The usage of modern thrusters allows combining the functions of the drive and the ship rudder in one unit, which are separated in conventional ship propulsion systems. The horizontally oriented propeller is supported in a vertically rotatable nacelle that is mounted underneath the ship's hull. The propeller can directly or indirectly be driven by an electric motor or combustion engine. Direct drive requires the installation of a low-speed electric motor in the nacelle. This present paper concentrates on indirect drives where the driving torque is transferred by bevel gear stages and shafts from the motor to the propeller.
The aim of the study was to apply such a specialized tooth contact analysis method, well-used within the steel gear community, to a polymer gear application to assess what modifications need be made to these models for them to be applicable to polymer gears.
In this paper local tooth contact analysis and standard calculation are used to determine the load capacity for the failure modes pitting, tooth root breakage, micropitting, and tooth flank fracture; analogies and differences between both approaches are shown. An example gearset is introduced to show the optimization potential that arises from using a combination of both methods. Difficulties in combining local approaches with standard methods are indicated. The example calculation demonstrates a valid possibility to optimize the gear design by using local tooth contact analysis while satisfying the requirement of documenting the load carrying capacity by standard calculations.
An experimental investigation on spur gears to characterize pitting degradation process using monitoring features.
Gear noise is among the issues of greatest concern in today's modern gearboxes. Significant research has resulted in the application of enhancements in all phases of gear manufacturing, and the work is ongoing. With the introduction of Electric Vehicles (EV), research and development in this area has surged in recent years. Most importantly, powerful new noise analysis solutions are fast becoming available.
"General Explanations on Theoretical Bevel Gear Analysis" is part 1 of an eight-part series from Gleason's Dr. Hermann Stadtfeld.
If a gear system is run continuously for long periods of timeâ€”or if the starting loads are very low and within the normal operating spectrumâ€”the effect of the start-up conditions may often be insignificant in the determination of the life of the gear system. Conversely, if the starting load is significantly higher than any of the normal operating conditions, and the gear system is started and stopped frequently, the start-up load may, depending on its magnitude and frequency, actually be the overriding, limiting design condition.
Micropitting has become a major concern in certain classes of industrial gear applications, especially wind power and other relatively highly loaded, somewhat slow-speed applications, where carburized gears are used to facilitate maximum load capacity in a compact package. While by itself the appearance of micropitting does not generally cause much perturbation in the overall operation of a gear system, the ultimate consequences of a micropitting failure can, and frequently are, much more catastrophic.
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.
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).
Natural resourcesâ€”minerals, coal, oil, agricultural products, etc.â€”are the blessings that Mother Earth confers upon the nations of the world. But it takes unnaturally large gears to extract them.
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.
Environmentally friendly cutting fluids aren't just good for the environment. They can also be good for performance.
The October 2011 issue of Gear Technology featured the article â€śLow-Distortion Heat Treatment of Transmission Components,â€ť 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.
Uncertainty casts a shadow over future business opportunities for manufacturers serving the new energy markets.
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.
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?
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.
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.
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 development of a new gear strength computer program based upon the finite element method, provides a better way to calculate stresses in bevel and hypoid gear teeth. The program incorporates tooth surface geometry and axle deflection data to establish a direct relationship between fillet bending stress, subsurface shear stress, and applied gear torque. Using existing software links to other gear analysis programs allows the gear engineer to evaluate the strength performance of existing and new gear designs as a function of tooth contact pattern shape, position and axle deflection characteristics. This approach provides a better understanding of how gears react under load to subtle changes in the appearance of the no load tooth contact pattern.
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.
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.
Industry battles it out for World's Largest Gear title.
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.
The oil industry is (pardon the pun) tanking. That may conjure up horrific images of other industries following suit in a domino effect of collective collapse into the overabundant oil slick the industry is currently drowning in, but not everyone is getting knocked down alongside the oil sector.
Oil-out conditions, or conditions in which an aircraft is operating without any oil in its gearbox or transmission, are devastating for an aircraft's hardware. Even the sturdiest gears usually can't last 30 minutes under such conditions before they catastrophically fail, and the whole system usually follows shortly after. That doesn't leave pilots with a whole lot of time to find a suitable location to land in the case of an oil-out emergency.
Amidst the energy industry's uncertain future, gearbox manufacturers are focusing on supplying the aftermarket.
Base oils play an important role in determining the performance of an industrial gear oil. They influence characteristics such as low temperature performance, biodegradability, energy efficiency and high temperature thermal and oxidative stability.
The oil-off (also known as loss-of-lubrication or oil-out) performance evaluation of gears is of significant interest to the Department of Defense and various rotorcraft manufacturers, so that the aircraft can safely land in an accidental loss-of-lubricant situation. However, unlike typical gear failure modes such as pitting or bending fatigue where early detection is possible, gear failure in an oil-off situation is very rapid and likely catastrophic. Failures rapidly result in the loss of torque transmission and the inability to control the aircraft.
Gear engineers have long recognized the importance of considering system factors when analyzing a single pair of gears in mesh. These factors include important considerations such as load sharing in multi-mesh geartrains and bearing clearances, in addition to the effects of flexible components such as housings, gear blanks, shafts and carriers for planetary geartrains. However, in recent years, transmission systems have become increasingly complexâ€”with higher numbers of gears and componentsâ€”while the quality requirements and expectations in terms of durability, gear whine, rattle and efficiency have increased accordingly.
In this article the authors present a loaded tooth contact analysis (LTCA) method for asymmetric gears that provides an accurate and efficient design tool for analyzing and comparing designs. The presented method is implemented in SMT's MASTA software. The authors also present an example comparative study using this tool for an automotive application.