Influence of the metalworking fluid on the running behavior of gear analogy test parts

Abstract

Boundary layers protect tooth flanks from solid-state contacts and, therefore, influence friction and wear. The characteristics of boundary layers (e.g. structure, chemical composition) and the running behavior of gears are determined by the manufacturing process (Klocke and Broeckmann in Prod Eng Res Dev 8(461):468, 2014; Brecher et al. in Prod Eng Res Dev 7:265–274, 2013). In this paper, the influence of the grinding fluid on the modification of boundary layers is shown. Analogy test parts are manufactured with varying fluids and additives. The differently ground test parts are measured regarding their boundary layer properties. Furthermore, the effects of the different resulting boundary layers on the running behavior are evaluated in finite life fatigue testing (pitting) on the two-disk test rig. By combining both measurement and test results, possible correlations between manufacturing and operation are investigated to establish a more sustainable and economical design of gears.