Improved mixed elastohydrodynamic lubrication of hypoid gears by the optimization of manufacture parameters

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Extensive wear appears in the case of dry contacts, or when the lubrication of the contacting surfaces is not appropriate. The aim of this research is to improve the mixed elastohydrodynamic lubrication in hypoid gears by the optimization of manufacture parameters for tooth surface processing. A full numerical analysis of the thermal mixed EHL in hypoid gears is applied. The equation system and the numerical procedure are unified for a full coverage of all the lubrication regions including the full film, mixed, and boundary lubrication. In the hydrodynamically lubricated areas the calculation method employed is based on the simultaneous solution of the Reynolds, elasticity, energy, and Laplace's equations. In the asperity contact areas the Reynolds equation is reduced to an expression equivalent to the mathematical description of dry contact problem. The real geometry and kinematics of the gear pair based on the manufacturing procedure is applied, thus the exact geometrical separation of the mating tooth surfaces is included in the oil film shape, and the real velocities of these surfaces are used in the Reynolds and energy equations. The transient nature of gear tooth mesh is included. The oil viscosity variation with respect to pressure and temperature and the density variation with respect to pressure are included. The non-Newtonian behaviour of the lubricant is considered. Using this model, the pressures, film thickness, temperatures, and power losses in the mixed lubrication regime are predicted. By using the developed method, the influence of the manufacturing parameters on the conditions of mixed elastohydrodynamic lubrication is investigated. On the basis of the obtained results recommendations are formulated to improve the mixed EHL and the efficiency of face-milled hypoid gears.

Original languageEnglish
Article number102722
Publication statusPublished - Nov 15 2019



  • Efficiency
  • Hypoid Gears
  • Manufacture
  • Mixed EHL
  • Pressure
  • Temperature

ASJC Scopus subject areas

  • Condensed Matter Physics
  • Mechanics of Materials
  • Surfaces and Interfaces
  • Surfaces, Coatings and Films
  • Materials Chemistry

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