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<p>This study investigates the influence of different friction modeling approaches on the gear contact behavior of spur gears made from a hybrid and porous (HyPo) steel-aluminium foam material combination. Two friction models are presented and integrated into a simulation framework: a fixed friction coefficient based on standard ISO/TS 6336-20 and a physically detailed model derived from elastohydrodynamic lubrication (EHL) theory incorporating asperity load share. The FE model enables the use of spatially graded material properties to represent the HyPo structure. The discussion of these approaches focuses on the advantages of the more detailed modeling approach as it incorporates the influence of tribological effects, such as local lubricant film thickness and surface topography. Particular attention is given to the implications for future applications in thermal simulation and wear prediction. The findings highlight the necessity of realistic tribological modeling in the simulation of novel, lightweight hybrid gear materials.</p>

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Simulation-based comparison of friction models in steel-aluminium foam spur gears

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年12月16日

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  • Maximilian Alexander Bähr,
  • Olaf Grutza,
  • Oliver Koch,
  • Manuel Oehler

摘要

This study investigates the influence of different friction modeling approaches on the gear contact behavior of spur gears made from a hybrid and porous (HyPo) steel-aluminium foam material combination. Two friction models are presented and integrated into a simulation framework: a fixed friction coefficient based on standard ISO/TS 6336-20 and a physically detailed model derived from elastohydrodynamic lubrication (EHL) theory incorporating asperity load share. The FE model enables the use of spatially graded material properties to represent the HyPo structure. The discussion of these approaches focuses on the advantages of the more detailed modeling approach as it incorporates the influence of tribological effects, such as local lubricant film thickness and surface topography. Particular attention is given to the implications for future applications in thermal simulation and wear prediction. The findings highlight the necessity of realistic tribological modeling in the simulation of novel, lightweight hybrid gear materials.