Enhanced friction model for high-speed right-angle gear dynamics

The modeling of elastohydrodynamic lubrication friction and the analysis of its dynamic effect on right-angle gears, such as hypoid and spiral bevel types are performed in the present study. Unlike the classically applied empirical constant coefficient of friction at the contacting tooth surfaces, the enhanced physics-based gear mesh friction model is both spatial and time-varying. The underlying formulation assumes mixed elastohydrodynamic lubrication (EHL) condition in which the division and load distribution between the full film and asperity contact zones are determined by the film thickness ratio and load sharing coefficient. In the proposed time-varying friction model, the calculation of friction coefficient is performed at each contact grid inside the instantaneous contact area that is being subjected to mineral oil lubrication. The effective friction coefficient and directional parameters synthesized from the net frictional and normal contact forces are then incorporated into a nonlinear time-varying right-angle gear dynamic model. Using this model, the effect of friction on the gear dynamic response due to the transmission error and mesh excitations is analyzed. Also, parametric studies are performed by varying torque, surface roughness and lubrication properties to understand the salient role of tooth sliding friction in gear dynamics. The simulation results are included. But experimental verification is needed.