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Coatings are widely used in gears to keep interface from wearing excessively. The purpose of this paper is to study the effect of coating properties and working conditions on the pressure, the shear traction, stresses as well as the fatigue life of spur gear.

A numerical contact fatigue life model of a coated spur gear pair under elastohydrodynamic lubrication (EHL) is developed based on the characteristics of gear geometry and kinematics, lubrication conditions and material properties. Frequency response functions and the discrete convolute and fast Fourier transform (DC-FFT) algorithm are applied to obtain elastic deformation and stress. Mutil-axial fatigue criteria are used to evaluate the contact fatigue life based upon the predicted time-varying stress fields of coated bodies.

The maximum Mises stress decreases while the fatigue life increases as the coating modulus decreases. A thinner coating leads to a longer life and a smaller maximum Mises stress for hard coatings. The load has more significant effect on the contact fatigue life of soft coatings.

The developed model can be used to evaluate the contact fatigue life of coated gear under EHL and help designers analyze the effect of coating elastic modulus and thickness on the contact pressure, film thickness and stress.

Integrated vehicle health management has been developed for several years in different industries, to be able to provide the required inputs to determine the optimal maintenance operations depending on the actual health status of the system. The purpose of this paper is to demonstrate the potential of a physics-based model (PbM) for prognostics with a real case study, based on the detection of incipient faults and estimate the remaining useful life of a planetary transmission of an aircraft system.

Most of the research in the area of health assessment algorithms has been focused on data-driven approaches that are not based on the knowledge of the physics of the system, while PbM approaches rely on the understanding of the system and the degradation mechanisms. A physics-based modelling approach to represent metal-metal contact and fatigue in the gears of the planetary transmission of an aircraft system is applied.

Both the failure mode caused by metal-metal contact as caused by fatigue in the gears is described. Furthermore, the real-time application that retrieves the results from the simulations to assess the health of the system is described. Finally the decision making that can be executed during flight in the aircraft is incorporated.

The paper proposes an innovative prognostics health management system that assesses two important failure modes of the planetary transmission that regulates the speed of the generators of an aircraft. The results from the models have been integrated in an application that emulates a real system in the aircraft and computes the remaining useful life in real time.

This paper aims to investigate the effect of misalignment on wear of spur gears and on oil degradation using online sensors.

The misalignment effect on gears is created through a self-alignment bearing, and is measured using laser alignment system. Several online sensors such as Fe-concentration sensor, moisture sensor, oil condition sensor, oil temperature sensor and metallic particle sensor are installed in the gear test rig to monitor lubricant quality and wear debris in real time to assess gearbox failure.

Offset and angular misalignments are detected in both vertical and horizontal planes. The failure of misaligned gear is observed at both the ends and on both the surfaces of the gear teeth. Larger-size ferrous and non-ferrous particles are traced by metallic particle sensor due to gear and seal wear caused by misalignment. Scanning electron microscope (SEM) images examine chuck, spherical and flat platelet particles, and confirm the presence of fatigue (pitting) and adhesion (scuffing) wear mechanism. Energy-dispersive X-ray spectroscopy analysis of SEM particles traces carbon (C) and iron (Fe) elements due to gear failure.

Gear misalignment is one of the major causes of gearbox failure and the lubricant analysis is as important as wear debris analysis. A reliable online gearbox condition monitoring system is developed by integrating wear and oil analyses for misaligned spur gear pair in contact.

The non-stationary operational wind loads vary in time and site and has remarkable effect on wind turbine drive train. The purpose of this paper is to determine the effects of wind class 3 and 7 on the life of wind turbine drive train. The two-wind class 3 and 7 are described by average wind speed and weight factor and effects of two variables on wind energy generation and wind turbine drive train studied.

The load distribution method is used to calculate stress range cycles for wind class 3 and 7. To determine the rise of force on wind turbine drive train, the load cycle method is proposed. The fatigue damage model is studied with respect to influence of different wind speeds and wind shear factor and then results analysed accordingly. Also sensitivity analysis has been carried out to assess the percentage of drop of energy generation and rise of tangential force for wind class 3 and 7. Linear fit method is used to determine the inclination of wind variation and wind shear of wind class 3 and 7. In this regard, two practical wind sites fall under the wind class 3 and 7 and 1.5 MW wind turbine have been taken in to account.

The results showed that the average rise of force on wind turbine drive train is 37.5% which can influence the drop in energy 34.7% for wind class 3. Similarly, the results of wind class 7 are showing that the average rise in force and drop in energy found to be 49.05% and 51.16%, respectively. The wind class 7 have higher tendency of wind fluctuations and weight factor that can cause a damage to wind turbine drive train components. The results showed that when wind speed increases to rated power 11.5 m/s the damages occurred and remain steady. Similarly, when weight factor increased from 0.18 to onwards the damage occurred. The increased wind loads increased the tangential loads on the wind turbine decreased life of the gearbox.

The results of study suggest that wind turbine should be design according to site specific wind environment for maximum energy generation and lowers the wind loads on the drive train component.

The purpose of this study is to investigate the influence of surface texture on the subsurface characteristics of contact interfaces under elastohydrodynamic lubrication condition. As a typical contact form of gears and bearings, the optimization of friction characteristics at the elastohydrodynamic lubrication (EHL) interface has attracted the attention of scholars. Laser surface texturing is a feasible optimization solution, but there have been concerns about whether the surface texture of high-pair parts will affect their fatigue life.

To examine the impact of texture preparation on the subsurface characteristics of high-pair interfaces under EHL conditions, a point contact EHL model is developed that takes into account the effect of textured surface topography. The pressure and thickness of the oil film are calculated as input parameters under different loads and entrainment velocities. The finite element method is used to simulate the impact of textures with varying diameters, densities and depths on the subsurface characteristics of the elastohydrodynamic interface. According to ISO 25178, analyze the relationship between 3D topography parameters and subsurface characteristics and study the trend of friction characteristics and subsurface characteristics based on the results of the ball on disc friction tests.

The outcomes suggest that under different rotational velocity and load conditions, the textured surfaces exhibit improved friction reduction effects; however, the creation of textures can result in significant subsurface plastic deformation and local peeling. The existence of texture makes the larger stress zone in the subsurface layer closer to the surface, leading to fatigue failure near the surface. Reasonable design parameters can help enhance the attributes of the subsurface. A smaller Sa and a Str greater than 0.5 can achieve ideal subsurface properties on the textured surface.

This paper investigates the influence of surface texture on the friction and subsurface characteristics of EHL interfaces and analyzes the impact of surface texture on interface contact performance while achieving lubrication improvement functional characteristics. The results provide theoretical support for the optimization design and functional regulation of surface texture in EHL interfaces.

The peer review history for this article is https://publons.com/publon/10.1108/ILT-10-2023-0324/

This paper aims to address the coating and compound analysis of diamond-like carbon (DLC) on steel, to understand the frictional behavior in tribological gear systems presented in paper Part I. Here, the Ti and Zr modified DLC coating architectures are analyzed regarding their chemical, mechanical and thermophysical properties. The results represent a systematic analysis of the thermal insulating effect in tribological contact of DLC coated gears.

The approach was to evaluate the effect of the substitution of Zr through Ti at the reference coating ZrCg to TiCg and the effect on thermophysical properties. Furthermore, the influence of different carbon and hydrogen contents on the coating and compound properties was analyzed. Therefore, different discrete Ti or Zr containing DLC coatings were deposited on an industrial coating machine. Thereby the understanding of the microstructure and chemical composition of the reference coatings is increased.

Results prove comparable mechanical properties of metal modified DLC independent of differences in chemical compositions. Moreover, the compound adhesion between TiC_g/16MnCr5E was improved compared to ZrC_g/16MnCr5E. The effect of hydrogen content Ψ and carbon content x_c on the thermophysical properties is limited by Ψ = 18 at.% and x_c = 90 at.%.

The findings of the combined papers Part I and II show a high potential for industrial application of DLC on gears. Based on the results DLC coatings and gears can be tailored to each other.

Systematic analysis of DLC coatings were conducted to evaluate the effect of titanium, carbon and hydrogen on thermophysical properties.

The purpose of this paper is to present a new methodology, used for dynamic reliability analysis of a gear transmission system (GTS) of wind turbine (WT), which could be used for assembly decision-making of the parts with errors to improve the GTS’s performance.

This paper involves the dynamic and dynamic reliability analysis of a GTS. The history curves of dynamic responses of the parts are obtained with the developed gear-bearing coupling dynamic model considering the random errors, failure dependency and random load. Then, the surrogate models of the mean and standard deviation of responses are presented by statistics, rain flow counting method and corrected-partial least squares regression response surface method. Further, a novel dynamic reliability model based on the maximum extreme theory, a theory of sequential statistics, equivalent principles and the inverse transform theory of random variable sampling, is developed to overcome the limitations of traditional methods.

The dynamic reliability of GTS considering the different impact factors are evaluated. The proposed reliability methodology not only overcomes the limitations associated with traditional approaches but also provides good guidance to assembly the parts in a GTS to its best performance.

Instead of constant errors, this paper considers the randomness of the impact factors to develop the dynamic reliability model. Further, instead of the limitation of the normal distribution of the random parameters in the traditional method, the proposed methodology can deal with the problems with non-normal distribution parameters, which is more suitable for the real engineering problems.

Wind energy is one of the most promising and the fastest growing alternative-energy production technologies, which have been developed in response to stricter environmental regulations, the depletion of fossil-fuel reserves, and the world's ever-growing energy needs. This form of alternative energy is projected to provide 20 percent of the US energy needs by 2030. For economic reasons, wind turbines (articulated structures that convert wind energy into electrical energy) are expected to operate, with only regular maintenance, for at least 20 years. However, some key wind turbine components (especially the gearbox) tend to wear down, malfunction and fail in a significantly shorter time, often three to five years after installation, causing an increase in the wind-energy cost and in the cost of ownership of the wind turbine. Clearly, to overcome this problem, a significant increase in long-term gearbox reliability needs to be achieved.

While purely empirical efforts aimed at identifying shortcomings in the current design of the gearboxes are of critical importance, the present work demonstrates that the use of advanced computational engineering analyses, like the finite-element stress analysis and a post-processing fatigue-life assessment analysis, can also be highly beneficial.

The results obtained in the present work clearly revealed how a variety of normal operating and extreme wind-loading conditions can influence the service-life of a wind-turbine gearbox in the case when the service-life is controlled by the gear-tooth bending-fatigue.

The present work attempts to make a contribution to the resolution of an important problem related to premature-failure and inferior reliability of wind-turbine gearboxes.

This paper proposes an improved fatigue life analysis method for optimal design of electric multiple units (EMU) gear, which aims at defects of traditional Miner fatigue cumulative damage theory.

A fatigue life analysis method by modifying S–N curve and considering material difference is presented, which improves the fatigue life of EMU gear based on shape modification optimization. A corrected method for stress amplitude, average stress and S–N curve is proposed, which considers low stress cycle, material difference and other factors. The fatigue life prediction of EMU gear is carried out by corrected S–N curve and transient dynamic analysis. Moreover, the gear modification technology combined with intelligent optimization method is adopted to investigate the approach of fatigue life analysis and improvement.

The results show that it is more corresponded to engineering practice by using the improved fatigue life analysis method than the traditional method. The function of stress and modification amount established by response surface method meets the requirement of precision. The fatigue life of EMU gear based on the intelligent algorithm for seeking the optimal modification amount is significantly improved compared with that before the modification.

The traditional fatigue life analysis method does not consider the influence of working condition and material. The life prediction results by using the method proposed in this paper are more accurate and ensure the safety of the people in the EMU. At the same time, the combination of intelligent algorithm and gear modification can improve the fatigue life of gear on the basis of accurate prediction, which is of great significance to the portability of EMU maintenance.

The finite element method (FEM) has become the prevalent technique used for analyzing physical phenomena in the field of structural, solid and fluid mechanics. The output of scientific papers is fast growing and professionals are no longer able to be fully up‐to‐date with all the relevant information. The purpose of this paper is to provide a bibliographical review on the application of FEM in mechanical engineering, specifically for the analyses and simulations of gears and gear drives from the theoretical as well as practical points of view.

The following topics on gears and gear drives are handled from the computational points of view: gears in general, spur gears, helical gears, spiral bevel and hypoid gears, worm gears and other gear types and gear drives. The paper is organized into two parts. In the first one each topic is handled in a short text, relevant keywords are presented and current trends in applications of finite element techniques are briefly mentioned. The second part lists references of papers published for the period 1997‐2006.

This bibliography is intended to serve the needs of engineers and researchers as a comprehensive source of published papers on design, analysis and simulation of gears and gear drives.

The bibliography listed is by no means complete but it gives a comprehensive representation of different finite element applications on the subjects. It will save time for readers looking for information dealing with described subjects, not having an access to large databases or willingness to spend time with uncertain information retrieval.