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<p>Geometric stress concentration due to misalignment is one of the major contributors to accelerated gear failure. Radial and axial misalignment reduces the contact area and increases stress concentration, making it crucial to study their impact on the surface wear of the driver gear. In the present study, the effects of radial, axial, and combined misalignments on the pressure angle, contact ratio, and wear depth of the driver gear were investigated. To simulate wear depth, the tooth profile was discretized into multiple points, and the point-to-point sliding distance was calculated to determine the wear depth. MATLAB is used to simulate. The final wear depth was computed as the sum of the wear depths over several wear cycles, with contact conditions assumed to be constant throughout the cycles. The simulation results were validated by experimental findings. For the experiments, a test setup was developed, and tests were conducted at a constant load of 40 Nm and speed of 1200 rpm. The simulation and experimental results were in close agreement, with a deviation of 10.10 % for dedendum wear depth and 23.52 % for addendum wear depth. Additionally, it was found that misalignment increases the working pressure angle and reduces the contact ratio of the gear pair. Axial misalignment raises the contact pressure, leading to more surface wear. The study also examined how changes in contact ratio due to misalignment affect the meshing period of the number of teeth in contact. The results revealed that increased radial misalignment decreased the contact ratio, causing higher pressure and sliding wear in the single-tooth contact zone. Axial misalignment caused the contact zone to shrink, resulting in increased contact pressure and sliding wear throughout the mesh cycle. The combined radial-axial misalignment further reduced the contact ratio, leading to even higher contact pressure and sliding wear. With increasing radial misalignment (RM), pitch point shifts by 9.62 %, pressure angle reduces by 30.48 %, contact ratio decreases by 27.21 %, and contact pressure drops by 2.26 %. Axial misalignment (AM) increases contact pressure by 41.47 %, and pinion wear depth increases by 81.22 %. This research highlights the significant influence of contact ratio variation on gear wear due to misalignment, a factor often overlooked in existing studies.</p>

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Gear sliding wear: The role of radial, axial, and combined misalignment

  • 期刊论文

  • 发表日期：

    2025年9月4日

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  • Dharmender Jangra,
  • Parvesh Antil,
  • Pankaj Thakur,
  • Kumar Ankur

摘要

Geometric stress concentration due to misalignment is one of the major contributors to accelerated gear failure. Radial and axial misalignment reduces the contact area and increases stress concentration, making it crucial to study their impact on the surface wear of the driver gear. In the present study, the effects of radial, axial, and combined misalignments on the pressure angle, contact ratio, and wear depth of the driver gear were investigated. To simulate wear depth, the tooth profile was discretized into multiple points, and the point-to-point sliding distance was calculated to determine the wear depth. MATLAB is used to simulate. The final wear depth was computed as the sum of the wear depths over several wear cycles, with contact conditions assumed to be constant throughout the cycles. The simulation results were validated by experimental findings. For the experiments, a test setup was developed, and tests were conducted at a constant load of 40 Nm and speed of 1200 rpm. The simulation and experimental results were in close agreement, with a deviation of 10.10 % for dedendum wear depth and 23.52 % for addendum wear depth. Additionally, it was found that misalignment increases the working pressure angle and reduces the contact ratio of the gear pair. Axial misalignment raises the contact pressure, leading to more surface wear. The study also examined how changes in contact ratio due to misalignment affect the meshing period of the number of teeth in contact. The results revealed that increased radial misalignment decreased the contact ratio, causing higher pressure and sliding wear in the single-tooth contact zone. Axial misalignment caused the contact zone to shrink, resulting in increased contact pressure and sliding wear throughout the mesh cycle. The combined radial-axial misalignment further reduced the contact ratio, leading to even higher contact pressure and sliding wear. With increasing radial misalignment (RM), pitch point shifts by 9.62 %, pressure angle reduces by 30.48 %, contact ratio decreases by 27.21 %, and contact pressure drops by 2.26 %. Axial misalignment (AM) increases contact pressure by 41.47 %, and pinion wear depth increases by 81.22 %. This research highlights the significant influence of contact ratio variation on gear wear due to misalignment, a factor often overlooked in existing studies.