Abstract
PurposeThe purpose of this paper is to develop innovative geometry for gears aiming low power loss and easy manufacturing.Design/methodology/approachNew gear profiles were developed and studied, and gears were built accordingly and then tested using an FZG machine.FindingsResults from the experimental tests revealed the influence of the profile modifications on the operating temperature, thus on the efficiency of gears (in terms of power loss).Research limitations/implicationsStudied cases were limited to experimental gear models compliant to the FZG machine.Practical implicationsLow‐loss gears can be produced using common technologies and tools. Its design includes power loss minimization besides mechanical strength. The new gears are more environmentally friendly and can operate with lower power consumption, lower temperature, increasing gear and gear oil life.Originality/valueThis work contributes to the development of the “low‐loss gears” concept, adapting it to low‐cost manufacturing technologies. Finally, more efficient gears and gearboxes can be produced only by performing simple geometrical modifications to standard gears.
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