International Gear Conference 2014: 26th-28th August 2014, Lyon

1210 Pages·2014·279.038 MB·English

by  Philippe Velex

INTERNATIONAL GEAR CONFERENCE 2014
National Organising Committee
Jérôme BRUYERE INSA – LaMCoS
Christophe CHANGENET ECAM
Jean-Pierre DE VAUJANY INSA – LaMCoS
Michèle GUINGAND INSA – LaMCoS
Michel OCTRUE CETIM
Joël PERRET-LIAUDET ECL - LTDS
Joël RECH ENISE
Philippe VELEX INSA – LaMCoS
(Conference Chair)
Fabrice VILLE INSA – LaMCoS
International Organising Committee
Christian BRECHER University of Aachen, Germany
David DOONER University of Puerto-Rico, USA
Alfonso FUENTES Polytechnic University of Cartagena, Spain
Srecko GLODEZ University of Maribor, Slovenia
Carlo GORLA Politecnico di Milano, Italy
Haruo HOUJOH Tokyo Institute of Technology, Japan
Don HOUSER Ohio State University, USA
Ahmet KAHRAMAN Ohio State University, USA
Aizoh KUBO Research Institute for Applied Sciences, Kyoto, Japan
Teik LIM University of Cincinnati, USA
Geng LIU Northwestern Polytech. University, China
Susumu MATSUMOTO Waseda University, Japan
H. Nevzat OZGUVEN Middle East Technical University Ankara, Turkey
Robert PARKER Virginia Tech, USA
José PEDRERO UNED, Spain
Datong QIN Chongqing University, China
Bernd SAUER University of Kaiserslautern, Germany
Berthold SCHLECHT University of Dresden, Germany
Jorge SEABRA University of Porto, Portugal
Brian SHAW University of Newcastle, UK
Zhaoyao SHI Beijing University of Technology, China
Avinash SINGH General Motors, USA
Ray SNIDLE Cardiff University, UK
Karsten STAHL Technische Universität München, Germany
INTERNATIONAL GEAR CONFERENCE 2014
26–28 August 2014
Lyon Villeurbanne, France
Organised by:
AMSTERDAM (cid:2)BOSTON (cid:2)CAMBRIDGE (cid:2)HEIDELBERG (cid:2)LONDON
NEW YORK (cid:2)OXFORD (cid:2)PARIS (cid:2)SAN DIEGO
SAN FRANCISCO (cid:2)SINGAPORE (cid:2)SYDNEY (cid:2)TOKYO
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FOREWORD

Mechanical transmission components such as gears, rolling element bearings, CVTs,
belts, chains, etc. are present in every industrial sector and range from nano-gears to
multi-MW size gearboxes. Over recent years, increasing competitive pressure and
environmental concerns have provided an impetus for cleaner, more efficient and
quieter units. Moreover, the emergence of relatively new applications such as wind
turbines, hybrid transmissions and jet engines, to name but a few, has imposed further
constraints and generated stimulating challenges.

The 2014 International Gear Conference in Lyon (France) provided a forum for the
most recent advances in the field of modern mechanical transmissions. A significant
number of articles from all around the world and 4 keynote addresses by leading
researchers were presented and are compiled in these proceedings. These papers are
representative of the broad range of gear technology and applications including:

 Gear noise and vibration, experiments and simulations.
 New gear design.
 New manufacturing techniques.
 Design and simulation methods for gear transmissions.
 Gear materials, heat treatments and coatings.
 Power losses and efficiency in gearboxes, low-loss gears and minimum
lubrication.
 All relevant failure modes in gears such as pitting, micro-pitting, scuffing,
bending fatigue, etc.
 New lubricants, additives and lubrication methods.
 Interactions between tribological and dynamic behaviour; modelling of
damping.
 Testing - Development of specific test rigs and/or new test procedures.

We were not only delighted to welcome delegates from the 5 continents for fruitful
scientific discussions but we were also proud to promote the cultural and gastronomical
heritage of the city of Lyon.

Finally, we would like to express our sincere thanks to all the attendees, members of the
national and international organising committees, our industrial sponsors and
institutional partners (all listed in the preceding pages) without whose support the
organisation of such an event would not have been possible.

Prof. Philippe VELEX
Conference Chair
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© The author(s) and/or their employer(s), 2014
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INDUSTRIAL SPONSORS
The Organisers wish to thank the following organisations for their support:
High ratio transmissions – the key component for
future mechatronic systems

B.-R. Höhn
Technical University of Munich, Germany

Mechatronic systems are combinations of an electric engine, high-ratio transmissions
and a sophisticated electronic control unit. Most of the mechatronic systems are part of a
machine, where high torque is required on the output-shaft at low or very low speeds.
That means that the power demand is not very high, and a mechanical transmission
must be used to transfer the low torque from the electric engine to the high torque on
the output member.

In this presentation, three examples illustrating the solutions for these special
requirements are detailed. These are:

- Wind-turbines with high-ratio transmission with the main focus being efficiency
- Robots with high-ratio gears to drive the two main axes with the objective of
minimum backlash
- Seat adjustments for passenger cars with the main focus on low cost and reduced
volume.

Bernd-Robert Höhn is Emeritus Professor at the Technical
University of Munich. He worked on gear development
at Audi, Ingolstadt from 1979 to 1989. He is the former
Director of the Gear Research Centre (FZG, 1989-2011) and
currently serves as CEO of ZG GmbH, specialized in driveline
systems with epicyclic transmissions. Prof. Höhn is the
coordinator for a SPP 1551 (Schwerpunktprogramm der DFG)
“Ressourceneffiziente Konstruktionslelemente” and leader of
the Evaluation-group GAG4 of the AIF (Arbeitsgemeinschaft
industrieller Forschungsvereinigungen). He is the leader for a
Koselleck-project of DFG “gears with no external lubricants”.

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© The author(s) and/or their employer(s), 2014
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Tribo-dynamic behavior of gear pairs

A. Kahraman
The Ohio State University, USA

Conditions dictating the tribological conditions of gear systems are coupled to the
dynamic behavior. There are various mechanisms coupling the dynamics to tribology of
gears. Tribology of the gear meshes determines the dynamic friction forces causing
vibrations along the off-line-of-action direction as well as dictating the damping at the
gear mesh. At the same time, vibratory motions as well as dynamic loads at the gear
mesh interface impact the elastohydrodynamic lubrication conditions. Such two-way
interactions have often been neglected in the fields of gear dynamics and gear tribology.
This talk attempts to bring attention to such interactions through a simplified tribo-
dynamics model for a spur gear pair. An iterative computational scheme is used to
implement a gear mesh lubrication model and a gear pair dynamics model to
demonstrate this two-way relationship and quantify the impact of operating conditions,
surface roughness and lubrication characteristics on the tribo-dynamics response.

Ahmet Kahraman is the Howard D. Winbigler Professor of
Mechanical and Aerospace Engineering at The Ohio State
University. He is the Director of Gleason Gear and Power
Transmission Research Laboratory. He also directs Pratt &
Whitney Center of Excellence in Gearbox Technology. He
received his Ph.D. degree in Mechanical Engineering from Ohio
State in 1990. He worked for General Motors for 10 years before
moving to academia. His research focuses on several areas of
power transmission and gearing including gear system design
and analysis, gear and transmission dynamics, gear lubrication
and efficiency, wear and fatigue life prediction, and test
methodologies. His current research program is funded by an
industrial consortium of 70 companies as well as individual
grants from various companies and government agencies. He authored more than 150
papers on gear research. He was the past chairman of the ASME Power Transmission of
Gearing (PTG) Committee and Chairman of the 2007 and 2009 ASME PTG Conferences. He
was a former associate editor of ASME Journal of Mechanical Design and Mechanics Based
Design of Structures and Machines. He currently serves at the editorial boards of Journal of
Sound and Vibration and Journal of Multi-body Dynamics. He is a fellow of ASME.
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© The author(s) and/or their employer(s), 2014
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Influence of enveloping stressed volume and
trochoidal interference on durability of gear teeth

A. Kubo
Kyoto University, Japan

The magnitude of Hertzian contact pressure and minimum oil film thickness between
contacting tooth flanks is commonly accepted as a criterion to evaluate the surface
durability of gear tooth flanks. Recent trends in gearbox design include the reduction in
volume and in weight which have highlighted surface failure of dedendum that cannot
be adequately explained by a theory based solely on contact pressure and lubrication.
Surface failure in highly loaded pinion with small tooth numbers usually occurs on the
dedendum whereas the mating addendum tooth flank of the wheel is not damaged. The
surface and subsurface states of stress calculated by the elastic contact theory is
nevertheless symmetric at the surface and inside of both contacting bodies. The
difference between the deteriorations on the pinion tooth dedendum and those on the
mating tooth addendum on the wheel is so significant that it can hardly be explained by
hypotheses such as “oil trapping in cracks” or “the difference in slip and rolling
directions”. The traditional theory on material fatigue can also not explain this
difference in the initiation and progress of the failure. Moreover the tooth flank near the
lower end of contact limit on tooth form suffers often considerable trochoidal
interference and crush of wear debris. All those induce very high contact stress and
large heat on the surface that is enough to melt the steel. The surface temperature there
becomes very high and the hardness of material becomes low. Tooth failure is often the
result of positive feedback behavior of such dynamic system of surface failure. In this
presentation, I introduce many examples to understand such model of tooth flank
failures. I hope, many gear researcher have an interest in these failure modes and will
be encouraged to carry out research on this topic.

Aizoh KUBO is Emeritus Professor of Mechanical Engineering at
Kyoto University and is now the general manager of the Research
Institute for Applied Sciences, Kyoto, Japan. He has a consulting
office KBGT(Kubo’s Gear Technologies Co). He was a guest
member of FZG, 1972/73, TU Munich and was the chairman of
IFToMM Gear TC from 1994 to 1997. His main field of research is
design and trouble shooting of gears concerning failure and
vibration and noise problems. He also has interest in analyzing
gear tooth manufacturing and in development of measuring
technique for the geometrical accuracy of gears. He works mainly
in gear research group of the Japan Society of Mechanical Engineers. He received LA
MEDAILLE D'OR de la Profession, pour collaboration aux travaux des methodes de calcul a
l'ISO from the Syndicat National des Fabricants d'Engrenages et Constructeurs d'Organes
de Transmission, France, 1986. He also received research paper Awards 1991 and 2009
from JSME and Invention Prize from the Japan Institute of Invention and Innovation (JIII)
on the development of design method of railway traction gears, 2002. He received the
Dudley Award in 2011 by the PTG division of the ASME, USA.
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© The author(s) and/or their employer(s), 2014
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Gearbox power losses – Influence of lubricants,
tooth and casing geometry

J. Seabra
Faculdade de Engenharia da Universidade do Porto, Portugal

Power loss and heat evacuation mechanisms in gearboxes have been widely discussed.
Typically, the power loss sources are grouped in no-load and load dependent losses,
generated by gears, rolling bearings and seals, which are strongly dependent on
operating conditions (torque and speed), lubricant formulation and type of lubrication,
gear tooth geometry, type of rolling bearings and case design, among others.

Thus, modelling gearbox power loss is a complex task: several different sub-models and
parameters should be taken into account in order to obtain good predictions of the
power loss associated with each mechanism and of the overall gearbox power loss.
Furthermore, it is possible to measure accurately the overall power loss of a gearbox,
but it is quite difficult to measure the contribution related to each mechanism and each
mechanical component.

In this work several sub-models and experimental strategies are presented, discussed
and validated in order to:
 Accurately predict rolling bearing power loss, depending on rolling bearing
geometry, operating conditions and lubricant formulation.
 Predict the coefficient of friction between gear teeth, depending on the operating
conditions and lubricant formulation, and to predict the gear loss factor (Hv)
depending on gear tooth geometry.
 Predict and measure the no-load gearbox power loss for a particular gearbox
design, operating conditions and lubricant formulation.

These sub-models and experimental measurements are used to predict the power loss in
complex gearboxes with several stages, under significantly wide ranges of the operating
conditions.

Jorge Seabra is Professor of Mechanical Engineering at FEUP
(Faculdade de Engenharia da Universidade do Porto),
Portugal, and President of the Institute of Mechanical
Engineering and Industrial Management (INEGI). He
graduated from FEUP in 1981 and obtained a PhD in
Mechanical Engineering from INSA Lyon in 1988. He is a
member of STLE and his research topics comprise Contact
Mechanics, EHD Lubrication, Gears, Rolling Bearings, Cams,
Surface Failures - Wear, Micropitting, Scuffing, Lubricants,
Rheology, In-service Lubricant Analysis.
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© The author(s) and/or their employer(s), 2014
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