AGMA-06FTM08-2006.pdf
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1、06FTM08 An Evaluation of FZG Micropitting Test Procedures and Results for the Crowned AGMA Test Gears by: Dr. D.R. Houser, S. Shon and J. Harianto, The Ohio State University TECHNICAL PAPER American Gear Manufacturers Association Copyright American Gear Manufacturers Association Provided by IHS unde
2、r license with AGMA Licensee=Boeing Co/5910770001 Not for Resale, 07/25/2008 03:20:21 MDTNo reproduction or networking permitted without license from IHS -,-,- An Evaluation of FZG Micropitting Test Procedures and Results for the Crowned AGMA Test Gears Dr. Donald R. Houser, Sam Shon, and Jonny Hari
3、anto, The Ohio State University The statements and opinions contained herein are those of the author and should not be construed as an official action or opinion of the American Gear Manufacturers Association. Abstract This paper discusses the process of developing an understanding of the stresses a
4、nd wear predictors using durability tests, with a focus on micropitting. The FVA Information Sheet No. 54/I-IV was used as an initial procedure, and later modified due to the higher contact stress levels predicted for the crowned AGMA test gears. A new procedure involving strain-gaging shafts on the
5、 FZG test machine was developed to produce better repeatability as well as more precise setting of load levels. Additionally, two oils were used and the micropittingwearamountsarecompared. Topographymeasurementsoftoothprofiles,predictionsofcontact stresses and contact patterns, and comparisons of mi
6、cropitting wear to these parameters as well as to flash temperatures and local film thickness are made. Copyright 2006 American Gear Manufacturers Association 500 Montgomery Street, Suite 350 Alexandria, Virginia, 22314 October, 2006 ISBN: 1-55589-890-4 Copyright American Gear Manufacturers Associat
7、ion Provided by IHS under license with AGMA Licensee=Boeing Co/5910770001 Not for Resale, 07/25/2008 03:20:21 MDTNo reproduction or networking permitted without license from IHS -,-,- 1 An Evaluation of FZG Micropitting Test Procedures and Results for the Crowned AGMA Test Gears Dr. Donald R. Houser
8、, Sam Shon, and Jonny Harianto, The Ohio State University Introduction This paper reports on the surface fatigue testing of gears that were manufactured as a part of the AGMA macro-pitting and tribology testing program 1. The overall goal of this work is to develop mod- els for predicting micropitti
9、ng wear and to ascertain the appropriateness of the AGMA test gears for mi- cropitting wear evaluation. As part of this goal, the study reported upon in this paper focuses on devel- oping an understanding of the stresses and wear predictors using FZG durability tests. Since the fo- cus is on micropi
10、tting, the first tests used the meth- od described in FVA Information Sheet No. 54/I-IV 2. Later, the procedure was modified to account for the much higher contact stress levels that are predicted for the heavily crowned and tip relieved AGMA test gears. This paper provides extensive analysis that i
11、ncludes detailed topography mea- surements of the tooth profiles, predictions of con- tact stressesand contactpatterns, anddiscussions regarding factors that affect contact stresses, flash temperatures and local film thickness of the tested gears. Testing Summary Thegearstestedinthisstudyarepartofth
12、esecond set ofgears manufacturedby AGMAand haveseri- al numbers, 150 to 159.Since this study was a “learning experience” using the heavily modified AGMA test spur gears,the testingprogram wases- sentiallyaworkinprogress, withinitial resultscaus- ing methodologies to change as we progressed. Listed b
13、elow is a summary of the tests that were performed with their results: 1. Staged loading at the FVA loading stages: Loads were at the low end of the range used by OConnor 1, Hoeprich 3, and Buzydon and Cardis 4 so they were felt to be a reasonable starting point.Results showed micropitting wear and
14、topographychange evenat thelowest loads, while at higher loads, macropitting oc- curred. Also, a peculiar “T-shaped” contactpat- tern was observed. 2. Based on the above results, more detailed stress predictions were made, a more detailed study of the FZG loading procedure was per- formed, and the p
15、rocedure for measuring tooth wear at each loading stage was refined. 3. Further tests were performed with staged load- ing,butatloadlevelsthatcompensateforthein- creased contact stresses of the crowned gears. Micropitting still occurred, causing further con- cern about the predicted contact stresses
16、. 4. Using revisedloading stages,a higherviscosity, EPlubricant(ISOviscositygrade220)wasused as a replacement for the MIL L 23699 lubricant that was used inthe previoustests. Micropitting wear was much less, but still occurred at the higher loading stages. Tooth Topographies The tooth geometry of th
17、e test gears is shown in Table 1 and the print specifications for leads and profilesareshowninFigs.1and2. Theleadspecifi- cation of the test gear is straight with a tolerance of 0.005 mm. It should be noted that the major “break” of the tip relief is about halfway between the highest point of single
18、toothcontactandthetipofeachtooth.Figs.3 and 4 show lead and profile measurements on four teeth of each gear. Comparing the charts, the pro- filesandleadsare madevery closeto thespecifica- tion, however, the lead crown appears to be slightly greater than the specification. As will be shown lat- er,th
19、emeasuredvalueofleadcrowndependsupon where on the tooth height the measurement is tak- en. During initialtesting ofthe gears,a ratherpecu- liar, T shaped contact pattern that is shown in Fig.5 appeared, thus implying that the tooth topography was not as simple as expected from the original in- spect
20、ioncharts.Therefore,moreextensive measurements of the tooth topographies were performed. Copyright American Gear Manufacturers Association Provided by IHS under license with AGMA Licensee=Boeing Co/5910770001 Not for Resale, 07/25/2008 03:20:21 MDTNo reproduction or networking permitted without lice
21、nse from IHS -,-,- 2 Figure 1: Profile and lead specifications for AGMA test pinion 5 Figure 2: Profile specification for AGMA test gear 5 Table 1: Geometry of AGMA Test Gear Sets 5 DimensionUnitPinion (Gear1) Gear (Gear2) Number of Teeth-2030 Modulemm3.62857 Center Distancemm91.5 Pressure Angledeg2
22、0 Contact Ratio-1.58 Face Widthmm1420 Outside Diametermm81.64116.36 Root Diametermm64.33899.162 Base Diametermm68.194102.29 3 Operating Pitch Diameter mm73.57108.86 Standard Pitch Diameter (SPD) mm73.20109.80 Tooth Thickness at SPD mm6.4155.072 SAP Roll Angledeg9.28012.111 EAP Roll Angledeg37.71031.
23、065 Figure 3: Standard Lead and Profile Measurements of the Pinion Copyright American Gear Manufacturers Association Provided by IHS under license with AGMA Licensee=Boeing Co/5910770001 Not for Resale, 07/25/2008 03:20:21 MDTNo reproduction or networking permitted without license from IHS -,-,- 3 F
24、igure 4: Standard Lead and Profile Measurements of the Gear Fig. 6 shows such a set of measurements on one tooth,where16leadchartsareshownononegraph and 16 profiles are shown on the other graph. The lead crown varies from 0.02 mm at the root to 0.06 mm at the tooth tip. This would imply that tool sh
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