Experimental investigation of churning power loss of single start worm gear drive through optimization technique

Chothani, Hardik G; Maniya, Kalpesh D.

doi:10.1016/j.matpr.2019.12.365

Cited by 12 publications

(11 citation statements)

References 10 publications

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“…Power losses in gear transmission vary extensively, which depends on many influencing factors, the most important of which are the type of material of meshed gears, geometry of worm pair, gear velocity, type and viscosity of lubricating oil, load, shape of the worm, operating temperature, etc. [10][11][12][13][14][15][16][17]. Based on DIN3996 standard [18], power losses in worm gearbox can be divided into load-dependant losses (mechanical losses) and load-independent losses.…”

Section: Introductionmentioning

confidence: 99%

The Impact of Lubricant Viscosity and Materials on Power Losses and Efficiency of Worm Gearbox

et al. 2022

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The results of the experimental research of the power losses and efficiency of single-stage worm gearbox, which is designed for such purpose, are presented in this paper. Three worm pairs (coupled gears) ZI type with the same geometric characteristics were used in the research, where worms are made of the same material (hardened and ground steel type 42CrMo4) and worm gears are made of three different types of material (zinc-aluminium alloy ZA12, aluminium alloy A356 and tin bronze CuSn12). The main part of the research is conducted to investigate the application of new materials for the manufacturing of worm gears (alloys ZA12 and A356) and their impact on the power losses and efficiency in comparison to tin bronze CuSn12. The values of efficiency are determined for different operating modes of the gearbox, that is, for different values of input rotational speed and load, where different viscosity lubricants were used. Depending on the operating mode and measured operating temperatures, the calculation of power losses and coefficient of friction for all experimental worm pairs was performed. Based on the obtained results, it can be concluded that the best tribological characteristics has worm pair 42CrMo4/ZA12, which is the recommendation for the use of ZA alloy for manufacturing of worm gears as the alternative for tin bronze and other non-ferrous metals.

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Section: Introductionmentioning

confidence: 99%

The Impact of Lubricant Viscosity and Materials on Power Losses and Efficiency of Worm Gearbox

et al. 2022

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“…Worm gears are used in a variety of applications, including industrial, heavy equipment, and even consumer products. Despite their low efficiency, they may produce extremely high reduction ratios and are in many situations self-locking [1]. The power losses in gear are split into two categories: (i) load-dependent (mechanical) and (ii) load-independent (spin) power losses due to windage losses, oil churning losses, and gear and bearing oil sealing losses.…”

Section: Introductionmentioning

confidence: 99%

“…Terekhov [7] and Boness [8] were one of the first to investigate the churning losses in dip-lubricated geared transmissions for a wide range of operating conditions. The churning torque is expressed in terms of dimensionless drag torque C m as Equation (1). They introduced several empirical equations based on different Reynolds and Froude numbers which are shown in Equations ( 2) to (4).…”

Section: Introductionmentioning

confidence: 99%

A model formulation for the prediction of churning power loss in worm gear transmission

Chothani¹,

Maniya²

2022

tribomat

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Churning power loss is a complex process that causes significant loss of energy under splash lubrication of gear units. A set of empirical equations are available that allows for precise churning power losses calculation for only the parallel axis gears. The main objective of this study is to formulate a new mathematical model for worm gear based on the experiment result. The mathematical model is formulated using the dimensional analysis method and has been experimentally validated over a wide range of speeds in terms of revolutions, types of lubricants, lubricant temperature, and immersion depths. The simple direct torque measurement method was used to measure the churning loss. The influence of inertia force, viscous force, and gravitational forces were also investigated therefore correlations with Froude and Reynolds numbers are presented. Hardened steel and bronze were used as a material combination of worm and worm gear, respectively. A new formula for worm gear under splash lubrication has been derived and validated by comparison with experimental evidence. A very little discrepancy was found between the experiment result and the mathematical equation.

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“…It is easy to deduct that the churning loss can occur in any rotating machinery. Unlike the studies on disks or gears submerged in fluids, which have been carried out for decades, whether in analytical modeling [17][18][19], CFD simulations [20][21][22], or experimental investigations [23,24], the churning loss phenomenon in hydraulic components has not been fully considered until it has become prominent when the rotational speed reaches a high level. Due to the high power-weight ratio requirement in the aeronautic and astronautic industries, hydraulic pumps, especially piston pumps, are designed for adapting super high rotational speeds.…”

Section: Introductionmentioning

confidence: 99%

Investigation of the Churning Loss Reduction in 2D Motion-Converting Mechanisms

et al. 2021

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In recent years, two dimensional (2D) hydraulic components have significantly flourished. After a brief development introduction of the 2D pump and 2D flowmeter, it could be concluded that the churning loss, which is caused by the rotational motion of 2D motion-converting mechanisms, has an increasing effect on reducing energy losses. This paper first presents a new 2D motion-converting mechanism and introduces its structure and working principles. To compare it with the former 2D motion-converting mechanism, the same working conditions were applied when designing the new one. Afterward, the generated churning loss by the active parts of the mechanism, such as the new rotor, was well studied by establishing a simplified CFD simulation model and was also verified to have a smaller churning loss than that of the former mechanism. As another key simulation result, the influence of the axial motion of the new rotor was found to be negligible for the churning loss even when the rotational speed was high enough. A test rig was subsequently built up to prove the simulation by monitoring the torque at various rotational speeds. As a result, the churning losses that took place in the new 2D motion-converting mechanism were certainly reduced, and the potential reasons for that were analyzed, as shown in the conclusion section.

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Experimental investigation of churning power loss of single start worm gear drive through optimization technique

Cited by 12 publications

References 10 publications

The Impact of Lubricant Viscosity and Materials on Power Losses and Efficiency of Worm Gearbox

The Impact of Lubricant Viscosity and Materials on Power Losses and Efficiency of Worm Gearbox

A model formulation for the prediction of churning power loss in worm gear transmission

Investigation of the Churning Loss Reduction in 2D Motion-Converting Mechanisms

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