Abstract
Three axle gear oils (75W90-A, 80W90-A and 75W140-A), available on the market and labeled as “Fuel Efficient”, and two candidate products (75W85-B and 75W90-B) were selected and their physical and chemical properties were measured and compared. The friction torque inside rolling bearings lubricated with the five axle gear oils was measured in a dedicated test rig. The measurements and the corresponding numerical simulations indicate that friction torque inside rolling bearings is strongly dependent on the operating conditions and on the axle oil formulations. The model was then applied with success to predict the torque loss in gearbox rolling bearings, in particular, those used in the FZG machine slave and test gearboxes. Gear power loss tests were realized on the FZG gear test machine, using type A10 gears and severe operating conditions. The torque loss measurements and the corresponding numerical simulations clearly pointed out the influence on the base oil type, of the oil viscosity and of the additive package on gear torque loss promoted by different axle oil formulations. An average coefficient of friction between meshing gears was devised from the experimental results. Several aspects regarding the meshing gears power loss were investigated like gear loss factor, the coefficient of friction and the influence of gear oil formulation (axle gear oils). A gearbox total power loss can be predicted by estimating the several power loss sources dissipated in gears, bearings and seals.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
Abbreviations
- a:
-
Axis distance [mm]
- b:
-
Gear face width [mm]
- da:
-
Tip diameter [m]
- dsh:
-
Shaft diameter [m]
- Fbt:
-
Transverse force to tooth flank [N]
- HV:
-
Gear loss factor [–]
- HVL:
-
Local gear loss factor using rigid load distribution [–]
- KFZG:
-
FZG load stage [–]
- m:
-
Gear module [mm]
- n:
-
Rotational speed [rpm]
- PIN:
-
Input power [W]
- PV:
-
Total power loss [W]
- PexpV:
-
Experimental total power loss [W]
- PVD:
-
Seals power loss [W]
- PVL:
-
Rolling bearings power loss [W]
- ρredC:
-
Equivalent contact radius on the pitch point [mm]
- PVZ0:
-
Gears power loss [W]
- PVZP:
-
Load dependent gears power loss [W]
- Ra:
-
Average surface roughness [m]
- TW:
-
Wheel static torque [Nm]
- x:
-
Addendum modification coefficients [–]
- \(v_{{\Sigma c}}\) :
-
Sum of the rolling velocities on the pitch point [m/s]
- XL:
-
Friction coefficient lubricant parameter [–]
- Z:
-
Number of teeth of pinion or gear [–]
- α:
-
Pressure angle [°]
- β:
-
Gear helix angle [°]
- η:
-
Dynamic viscosity [Pas]
- εγ:
-
Total contact ratio [–]
- μbl:
-
Coefficient of friction in boundary film lubrication [–]
- μEHL:
-
Coefficient of friction in full film lubrication [–]
- μmz:
-
Average friction coefficient along the path of contact [–].
References
Hammami M, Martins R, Fernandes C, Seabra J, Abbes MS, Haddar M (2018) Friction torque in rolling bearings lubricated with axle gear oils. Tribol Int 119:419–435. https://doi.org/10.1016/j.triboint.2017.11.018
Winter H, Michaelis K (1986) Scoring tests of aircraft transmission lubricants at high speeds and high temperatures. J Synth Lubr 3(2):121–135. https://doi.org/10.1002/jsl.3000030205
14635-2 (2004) I. FZG test procedures–Part 2: FZG step load test A10/16, 6R/120 for relative scuffing load-carrying capacity of high EP oils
Fernandes CM, Martins RC, Seabra JH (2014) Torque loss of type C40 FZG gears lubricated with wind turbine gear oils. Tribol Int 70(0):83–93. https://doi.org/10.1016/j.triboint.2013.10.003. ISSN 0301-679X
Kolekar AS (2013) Lubrication & efficiency of rear wheel drive axles in road vehicles. PhD. thesis
Hammami M, Martins R, Abbes MS, Haddar M, Seabra J (2017) Axle gear oils: Tribological characterization under full film lubrication. Tribol Int 106:109–122
Hohn B-R, Michaelis K, Vollmer T (1996) Thermal rating of gear drives: balance between power loss and heat dissipation. AGMA Technical Paper
Hohn, B-R, Michaelis K, Hinterstoißer M (2009) Optimization of gearbox efficiency. Goriva imaziva, 48(4):462
Simrit (1976) Radialwellendichtringe, Kataog Nr. 100
Ohlendorf H (1958) Verlustleistung und Erwärmung von Stirnrädern. PhD. thesis, Dissertation TU München
Hammami M (2017) Efficiency and wear in automotive gear transmissions. PhD. thesis, National School of Engineers of Sfax
Schlenk L (1994) Unterscuchungen zur Fresstragfähigkeit von Grozahnrädern. PhD. thesis, Dissertation TU Munchen
Acknowledgements
The authors gratefully acknowledge the funding supported by National Funds through projects NORTE-01-0145- FEDER-000022—SciTech—Science and Technology for Competitive and Sustainable Industries, co-financed by Programa Operacional Regional do Norte (NORTE2020), and Fundo Europeu de Desenvolvimento Regional (FEDER) and LAETA under the project UID/EMS/50022/2013.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2020 Springer Nature Switzerland AG
About this paper
Cite this paper
Hammami, M., Abbes, M.S., Martins, R., Seabra, J.H.O., Haddar, M. (2020). Power Losses in a Gearbox Lubricated with Axle Gear Oils. In: Aifaoui, N., et al. Design and Modeling of Mechanical Systems - IV. CMSM 2019. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-030-27146-6_27
Download citation
DOI: https://doi.org/10.1007/978-3-030-27146-6_27
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-030-27145-9
Online ISBN: 978-3-030-27146-6
eBook Packages: EngineeringEngineering (R0)