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The finite element method has been increasingly applied in stress, thermal and dynamic analysis of gear transmissions. Preparing the models with different design and modification parameters for the finite element analysis is a time-consuming and highly skilled burden.

To simplify the preprocessing work of the analysis, a parametric finite element modeling method for spur and helical gears including profile and lead modification is developed. The information about the nodes and elements is obtained and exported into the finite element software to generate the finite element model of the gear automatically.

By using the three-dimensional finite element tooth contact analysis method, the effects of tooth modifications on the transmission error and contact stress of spur and helical gears are presented.

The results demonstrate that the proposed method is useful for verifying the modification parameters of spur and helical gears in the case of deformations and misalignments.

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 purpose of this paper is to investigate the thermal elastohydrodynamic lubrication (TEHL) flash temperature of the helical gear pairs considering profile modification.

A flash temperature model of the helical gear pair considering the profile modification is proposed based on the TEHL and meshing theories. In doing so, the slicing, fast Fourier transform and chase-after methods are applied to accurately and rapidly obtain the flash temperature of the gear pair. Then, the effects of the modification, input torque and rotation speed on the flash temperature are studied.

With the increment of the tip relief amount, the flash temperature of the helical gear pair with the axial modification decreases first and then increases, and the meshing position of the maximum flash temperature moves toward the pitch point. Moreover, reducing the input torque or increasing the rotation speed can efficiently reduce the TEHL flash temperature.

This work is a valuable reference for the profile design and optimization of the helical gears to avoid the excessive flash temperature.

The purpose of this paper is to develop innovative geometry for gears aiming low power loss and easy manufacturing.

New gear profiles were developed and studied, and gears were built accordingly and then tested using an FZG machine.

Results 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).

Studied cases were limited to experimental gear models compliant to the FZG machine.

Low‐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.

This 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.

The purpose of this paper is to investigate the dynamic responses of a spur gear pair with unloaded static transmission error (STE) excitation numerically and experimentally and the influences of the system factors including mesh stiffness, error excitation and torque on the dynamic transmission error (DTE).

A simple lumped parameters dynamic model of a gear pair considering time-varying mesh stiffness, backlash and unloaded STE excitation is developed. The STE is calculated from the measured tooth profile deviation under the unloaded condition. A four-square gear test rig is designed to measure and analyze the DTE and vibration responses of the gear pair. The dynamic responses of the gear transmission are studied numerically and experimentally.

The predicted numerical DTE matches well with the experimental results. When the real unloaded STE excitation without any approximation is used, the dynamic response is dominated by the mesh frequency and its high order harmonic components, which may not be result caused by the assembling error. The sub-harmonic and super-harmonic resonant behaviors are excited because of the high order harmonic components of STE. It will not certainly prevent the separations of mesh teeth when the gear pair is under the condition of high speed and heavy load.

This study helps to improve the modeling method of the dynamic analysis of spur gear transmission and provide some reference for the understanding of the influence of mesh stiffness, STE excitation and system torque on the vibration behaviors.

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.

The purpose of this paper is to make an attempt to evaluate the pitting load carrying capacity under increased thermal conditions. This is the basis for an estimated lifetime which is one of the most important parameters defining transmission reliability.

Recommendations related to pitting load carrying capacity calculation of case hardened gears running at high gear bulk temperatures are formulated. These factors are based on extensive experimental data, obtained in pitting tests with high oil injection temperatures, high oil sump temperatures or high operational gear bulk temperatures due to a lack of heat dissipation caused by minimised lubrication.

Testing of gear type C‐PT on FZG back‐to‐back test rig at high gear bulk temperatures by either heating up the lubricant or caused by a lack of heat dissipation as it appears with poor lubrication conditions resulted in a decrease of up to 30 per cent of the endurance strength in various investigations. This results in a reduction of the material strength due to tempering effects and high surface shear stress due to low oil film thicknesses caused by low operating oil viscosities.

The present calculation method in the standard DIN/ISO is not valid for high gear bulk temperatures. Nevertheless, the present calculation algorithms of the standards DIN/ISO are valid for low and moderate thermal operating conditions when using oil temperatures of up to 80 (90)°C in the case of a sufficient cooling oil supply to the gear mesh. With the presented modifications higher gear bulk temperatures (>120°C) can be taken into account.

The purpose of this paper is to establish a transient contact position prediction method of gears at the meshing point based on the equivalent contact model.

In this method, the contacting surface profiles are constantly updated by changing the pressure angle and the chord tooth thickness, which has a direct connection with the equivalent base circle radius. According to the equivalent base circle radius, the equivalent pressure angle at the pitch circle and equivalent pitch point can be calculated. The equivalent contacting surface profile is determined by the equivalent pressure angle at the pitch circle; for each meshing point, there is one equivalent pressure angle at the pitch circle. Therefore, each meshing point can be regarded as a point on the equivalent contacting surface profile.

The model is applicable to find out the contact position after a series of meshing cycles through the law of pressure angle change and intentionally kept as simple as possible with the aim to be used in further study of gear flanks at the point of the actual contact.

The results of the experiment are applied to the equivalent contact model to describe the transient contact position and assess the model accuracy.

The determination of the contact position of the worn tooth profile provides the action points of the force for the study of the contact fatigue.

Power loss is an important index to evaluate the transmission performance of a gear pair. In some cases, the starved lubrication exists on the gear contact interface. The purpose of this paper is to reveal the mechanical power loss of a helical gear pair under starved lubrication.

A starved thermal-elastohydrodynamic lubrication (EHL) model is proposed to evaluate the tribological properties of a helical gear pair. The numerical result has been validated against the published simulation data. Based on the proposed model, the influence of thermal effect, working conditions, inlet oil-supply layer and surface roughness on the mechanical power loss and lubrication performance has been discussed.

Results show that the thermal effect has a significant effect on the tribological properties of helical gear pair, especially on mechanical power loss. For a specified working condition, there is an optimal oil supply for gear lubrication to obtain the state of full film lubrication. Meanwhile, it reveals that the mechanical power loss increases with the increase of the surface roughness amplitude.

In this paper, a starved thermal-EHL model has been developed for the helical gear pair based on the finite line contact theory. This model can be used to analyze the tribological properties of gear pair from full film lubrication to mixed lubrication. The results can provide the tribological guidance for design of a helical gear pair.

GEAR oil testing is an enterprise involving large numbers of people and equipment and costing millions of dollars per year. It is used as a guide in the development of new gear lubricants (or even new machines) and also serves broad quality control purposes. Since the gear oil business is a multimillion dollar area and since it is serving a multibillion dollar automotive and industrial investment around the world, spending for gear oil testing can be well worth the costs. However, as in every other aspect of business, cost reduction in gear oil testing is becoming more and more a demand of the times. It is therefore important to take a critical look at the expenses incurred in this area, and decide if some of the tests can be eliminated without detrimental effects.