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A computational model is proposed for the prediction of friction-related mechanical efficiency losses of parallel-axis gear pairs. The model incorporates a gear load distribution model, a friction model, and a mechanical efficiency formulation to predict the instantaneous mechanical efficiency of a gear pair under typical operating, surface, and lubrication conditions. The friction model uses a new friction coefficient formula obtained by using a validated non-Newtonian thermal elastohydrodynamic lubrication (EHL) model in conjunction with a multiple linear regression analysis. The load and friction coefficient distribution predictions are used to compute instantaneous torque/ power losses and the mechanical efficiency of a gear pair at any given rotational position. Efficiency measurements from gear pairs having various gear designs and surface treatments are compared to model predictions. Mechanical efficiency predictions are shown to be within 0.1% of the measured values, indicating that the proposed efficiency model is accurate. Results of a parametric study are presented at the end to highlight the influence of key basic gear geometric parameters, tooth modifications, operating conditions, surface finish, and lubricant properties on mechanical efficiency losses.

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A dynamic model of a multi-shaft helical gear reduction unit formed by N flexible shafts is proposed in this study. The model consists of a finite element model of shaft structures combined with a three-dimensional discrete model of helical gear pairs. Bearing and housing flexibilities are included in the model as well. Eigenvalue solution and the Modal Summation Technique are used to predict the free and forced vibrations of the system. Results of experimental study on a helical gear-shaft-bearing system are also presented for validation of the model. It is demonstrated that the predictions match well with the experimental data in terms of excited modes and the forced response given in the form of the dynamic transmission error. Forced vibrations of an example system formed by three shafts are also studied to demonstrate the influence of some of the key system parameters.

A model to simulate the dynamic behavior of a single-stage planetary gear train with helical gears is developed. The three-dimensional dynamic model includes all six rigid body motions of the gears and the carrier. The generic nature of the formulation allows the analysis of a planetary gear set with any number of planets. Planets can be arbitrarily spaced (equally or unequally) around the sun gear. The model is also capable of handling different planet meshing conditions which are functions of number of gear teeth and planet positions. The linear time-invariant equations of motion are solved to obtain the natural modes and the forced vibration response due to static transmission errors. The proposed model is employed to describe the effects of the planet mesh phasing conditions on the dynamic behavior of a four-planet system.

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