Wear phenomena in worm gears are dependent on the size of the gears. Whereas larger gears are mainly affected by fatigue wear, abrasive wear is predominant in smaller gears. In this context a simulation model for abrasive wear of worm gears was developed, which is based on an energetic wear equation. This approach associates wear with solid friction energy occurring in the tooth contact. The physically-based wear simulation model includes a tooth contact analysis and tribological calculation to determine the local solid tooth friction and wear. The calculation is iterated with the modified tooth flank geometry of the worn worm wheel, in order to consider the influence of wear on the tooth contact. Experimental results on worm gears are used to determine the wear model parameter and to validate the model. A simulative study for a wide range of worm gear geometries was conducted to investigate the influence of geometry and operating conditions on abrasive wear.
As part of the Formula Student, students independently built new racing cars every year which compete in various disciplines. The Kaiserslautern Racing Team, founded in 2007, has developed and constructed a racing car under Formula Student regulations every year since their foundation. At first, vehicles with combustion engines were built, until in season 2011/2012, the change to electric engines was realized. One of the main objectives for the second electric vehicle (season 2012/2013) was a weight reduction by 100 kg, which required adjustments in all components. For the chassis, this meant a change from 13 to 10 inch rims which were to be bought from a commercial vendor.A three-piece rim from a US vendor was purchased. Since the installed rim stars showed excessive manufacturing tolerances, for the first time, self-constructed stars were produced and used with the purchased rim base.Although the rims were designed using an FEM program, as well as an high safety factor the component failed at a test run after the season.As part of the accompanying seminar to the lecture on damage analysis at TU Kaiserslautern, the cause of the rim failure was investigated. Here, the damage analysis was performed under VDI policy 3822.
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