Abstract
Coating is an effective way to reduce friction and wear and to improve the contact-fatigue lives of gear components, which further guarantees a longer service life and better reliability of industrial machinery. The fact that the influence coefficient linking the tractions and stress components could not be expressed explicitly increases the difficulty of coated solids contact analysis. The complicated tribological behavior between tooth surfaces influenced by lubrication and surface roughness further adds difficulty to the coated gear pair contact problems. A numerical elastohydrodynamic lubricated (EHL) contact model of a coated gear pair is proposed by considering the coupled effects of gear kinematics, coating properties, lubrication, and surface roughness. The frequency response function and the discrete convolute, fast Fourier transformation (DC-FFT) method are combined to calculate the surface deformation and the subsurface stress fields at each meshing position along the line of action (LOA). The Ree-Eyring fluid is assumed to incorporate the non-Newtonian effect, which is represented in the generalized Reynolds equation. Influences of the ratio between the Young’s modulus of the coating and the substrate on the contact performance, such as pressure, film thickness, tooth friction coefficient, and subsurface stress field, are studied. The effect of the root mean square (RMS) value of the tooth surface roughness is studied by introducing the roughness data, deterministically measured by an optical profiler.
Highlights
The development of the machinery industry is characterized by high speed, high load, and high power trends
Owing to the difference between the mechanical properties of coating and substrate, both the surface tribological behavior and subsurface stress field would change compared with the uncoated case
The elastic deformation or stress components can be calculated by the pressure distribution and the influence coefficients linked to them
Summary
The development of the machinery industry is characterized by high speed, high load, and high power trends. In order to get higher power densities and fatigue lives of gears, advanced technologies, such as case hardening [2] and shot peening [3], have been developed to augment the service lives or reduce the friction and wear Among these technologies, coating is an effective method that has been widely used in many industrial fields [4, 5]. A numerical elastohydrodynamic lubrication model based on the frequency response function and the DC-FFT method is presented in this paper to evaluate the distribution of pressure, film thickness, friction, subsurface stress field, etc., during the meshing process considering gear coating properties. Effects of the modulus ratio between the coating and the substrate and the root mean square (RMS) value of the surface roughness are studied
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