Abstract
This study explores accelerated gear failures due to misalignment-induced geometric stress concentration. A mathematical model is derived to assess misalignment effects on sliding wear of driver gears using MATLAB. The model's accuracy is validated against literature and experiments. A parametric study investigates the impact of design parameters on wear in combined misaligned gear pairs. Findings show that increasing radial misalignment raises pressure and sliding wear in the single-tooth contact zone, while axial misalignment decreases the contact zone, resulting in increased wear throughout the mesh cycle. Angular misalignment reduces the contact zone, leading to non-linear wear distribution along the tooth flank. Combined misalignment has the most severe effects, causing higher contact pressure, non-linear wear distribution, and increased wear in transition zones.
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