Abstract
Churning power loss is a complex process that causes significant loss of energy under splash lubrication of gear units. A set of empirical equations are available that allows for precise churning power losses calculation for only the parallel axis gears. The main objective of this study is to formulate a new mathematical model for worm gear based on the experiment result. The mathematical model is formulated using the dimensional analysis method and has been experimentally validated over a wide range of speeds in terms of revolutions, types of lubricants, lubricant temperature, and immersion depths. The simple direct torque measurement method was used to measure the churning loss. The influence of inertia force, viscous force, and gravitational forces were also investigated therefore correlations with Froude and Reynolds numbers are presented. Hardened steel and bronze were used as a material combination of worm and worm gear, respectively. A new formula for worm gear under splash lubrication has been derived and validated by comparison with experimental evidence. A very little discrepancy was found between the experiment result and the mathematical equation.
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