Mixed and thermal elastohydrodynamic simulation of a low-loss gear considering the gear system

The reduction of load-dependent gear power loss is one of the key aspects in modern gear design. Therefore, a detailed power loss prediction and the local investigation of its drivers is essential to use its full potential. In this study, the model of the author's previous work is stepwise enhanced to match the real contact conditions as close as possible. The impact of the eliminated simplification or assumption is shown at each of the individual enhancement steps. The proper choice of the lubricant parameters, the coefficient of solid friction and the gear system stiffness show the great impacts on load-dependent gear power losses and the local friction distribution. It is explained how the load-dependent gear power loss of an individual tooth contact is derived from the transient local TEHL contact and subsequently the measurable load-dependent gear power loss of the gear stage. Considering a low-loss gear geometry, the simulation results are compared with experimental results and shows a good level of conformity.