On the prediction of power loss in helical gearbox via simulation approach

Abstract

Abstract Frictional loss, load variation, viscosity and speed are major causes of power loss in helical gears under normal operating conditions. The study presents the major theoretical findings to predict the possible power loss in a helical gear box. First, an analytical technique was employed to model the frictional loss and coefficient of friction resulting from the heat generated for a pair of helical gear in mesh. Then, a finite element method and Comsol Multiphysics was applied to model the helical gear structure as well as the surface displacements under static and moving conditions of the pinion. It was observed that the highest amplitude in surface displacement was 14 × 10 − 6 (m) against when the pinion was stationary which is 20 × 10 − 6 (m). This can cause a significance wear depth and tooth surface pressure which eventually will lead to increase in fatigue. More so, As the frictional loss increase, there is an increase in the corresponding power loss factor with the highest being 180 for a frictional loss of 270. This shows that friction between a pair of meshing helical gear teeth influences power loss in a gearbox under normal operating condition. Thus, the results are an indication that good predictions during gear design would lead to a better gear transmission efficiency.