Global and local analysis of gear scuffing tests using a mixed film lubrication model

Abstract Gear tests were performed in a FZG test rig in order to evaluate the influence of the operating conditions (torque, speed and oil bath temperature), gear geometry and base oil viscosity on gear scuffing. A mixed film lubrication model was used to evaluate the normal pressures and shear stresses in several points along the gear meshing line, for each load stage and for all the gear scuffing tests performed. The gear scuffing results were analyzed using two different approaches: one considering global gear parameters defined at the meshing line scale and another based on local parameters at the roughness asperity scale, determined using the mixed film lubrication model. The analysis at the roughness asperity level was used to complete the scuffing study performed with global gear contact parameters, explaining the occurrence of scuffing during ‘running-in’, justifying the zones in teeth flanks where the first scuffing marks appear and supplying indicators for low scuffing resistance at high oil bath temperatures.

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