A Novel Tooth Surface Wear Prediction Model for Thin-webbed Gear Pairs Considering Manufacturing Errors

Aiming to investigate the influence of gear web structure and manufacturing errors on the dynamic tooth surface wear, a novel dynamic wear prediction model for thin-webbed gear pairs in consideration of manufacturing errors is established by deeply integrating the loaded tooth contact (LTCA) model, lumped-parameters dynamic model of gear systems, and Archard wear model. In the LTCA model, the finite element substructure method is utilized to obtain the flexibility matrix of the tooth surface considering the structural parameters of gear webs. The dynamic contact stress distribution can be obtained by introducing the dynamic mesh force into the LTCA model. The relative sliding distance between mating tooth surfaces can be obtained through gear kinematics, and the dynamic wear coefficient during gear wear process can be determined using regression formula. By substituting the obtained dynamic contact stress distribution, relative sliding distance, and dynamic wear coefficient into the Archard wear model, the tooth surface wear distribution can be determined. Due to the gradual changes in the micro morphology of tooth surface caused by gear wear, the tooth surface cyclic updating strategy is conducted during the wear process prediction. The influence of input speed, gear web parameters, wear cycles and lead modification on dynamic contact stress and dynamic tooth surface wear distribution are analyzed in depth.