Mixed Elastohydrodynamic Lubrication with 3D Machined Roughness in Spiral Bevel Gears
Spiral bevel gears are key components widely used for transmitting significant power. In reality, these gear surfaces are quite rough with three-dimensional topography that may significantly influence the lubrication formation and breakdown as well as components failures. Previous bevel gear lubrication studies, however, were limited to those under the assumption of full-film lubrication with smooth surfaces. In the present study a comprehensive analysis for gearing geometry, kinematics, mixed lubrication performance, friction, flash temperature and subsurface stresses in spiral bevel gears is developed based on a recently developed mixed EHL model that is capable of handling practical cases with 3D machined roughness under severe operating conditions and considering the effect of arbitrary entrainment angle. Obtained results from sample cases show that the model developed can be used as an engineering tool for spiral bevel gear design optimization and strength prediction.