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The friction between the teeth of a pair of hardened and ground spur
gears has been measured in a back-to-back test rig. The results are
compared with friction measurements using a disc machine under
comparable conditions of load, speed and temperature. Close agreement
was found with discs which had been transversely ground (like the gear
teeth); circumferentially ground discs to the same finish gave on average
23% higher friction.
22 / / /
Table 2
Range At pitch
point
), Relative radius of
curvature (p) m m 7.68-3.34 6.84
Rolling (entraining)
XXX X ~, X x v v ~" x K v v v x v Y
If f
speed
6=½(ul+v2),mm s 1
Sliding speed
(~1-u2),mm S 1
11.74ool-8.65ml
0
Slide/roll ratio (6) 0.76 - - 1 . 1 2 0
II I
W 1 N.B. ~ol is the pinion speed in rad s
/ \
|L
= I The surface finishes of the tooth surfaces were
measured by a Ferranti Surfcom profilometer using
acrylic replicas. Examples of these measurements are
shown in Fig 2 and Table 3 where they are compared
with measurements of the disc surfaces. The gears
have been in service for about four years (150 h
Fig 1 Back-to-back, 2:1 ratio, gear test rig. The drive intermittent running) with the driving torque always
is to the pinion shaft and the box is trunnion mounted in the same direction. Roughness measurements of the
so that the lost torque can be measured by spring unloaded faces of the teeth are included in Fig 2 which,
balance by comparison, indicate the effect on surface finish of
running under load.
The gears and discs were lubricated with a mineral
zero load permits them to be calibrated out. An oil without additives: Shell Vitrea 68. The viscous
estimate of the increase in bearing friction with load characteristics at the temperatures of the experiments
suggested that it is within the experimental error and are given in Table 4.
can be neglected.
Table 1
10/~m
Circumferentially ground disc (before running)
Pinion (1) Wheel (2)
Number of teeth (N) 24 48
Pitch circle radius (r) m m 30 60 E
A d d e n d u m = module m = 2.50 m m ; pressure angle 4)= 20°; Circumferentially ground disc (after running) ~ 10 #m
face width = 5.84 ram; contact ratio rc = 1.67; base circle
pitch p~ = 7.38 m m Fig 2 Surfcom traces of gear teeth and discs
270 October 91 Vol 24 No 5
K. L. Johnson and D. I. Spence--Determination of gear tooth friction by disc machine
25 0.135 2.18 x 10 8
0.6
50 0.037 1.94 x 10 -8
E
z 0.4
G e a r t e s t results ~r
Table 5 drive the discs and bearings under load, but without
transmitted torque. Half this measured torque is
Disc machine ascribed to each pair of bearings.
Gear
Circumferential Transverse test Test discs
Discs of 76 mm diameter and 12.7 mm track width
Temp, Rolling Contact We ~e We ~e were machined from tool steel hardened to ~ 800 VPH
°C s p e e d , pressure, and ground. One pair was ground transversely using
ms 1 MNm 2 a cup grinding wheel and a second pair was ground
circumferentially in the conventional way. Both pairs
were polished slightly to give approximately the same
25 0.43 683 0.087 CLA roughness as the gear teeth (see Fig 2 and Table
0,054 l
828 0.085 0.086 0.057 0,057 0.056 3).
940 0,087 0.060
0.86 683
828
0.065
0.069
0.049 ]
0,068 0.053 0.053 0.052
The same lubricant was used as in the gear tests.
8
, + ] . 0060 =t
0.056
0052
~"
4~ 12
1o
K. L. Johnson and D. I. Spence--Determination of gear tooth friction by disc machine
+ I + I I . 0.087 C"
.9
0.054 '~
~4 x ~ 0044 ~j
E I! 0"43ms 1 ~- '~'
6 0.86 m s-1 ~;
£3 1.26 m s-1 c~
[ i 0.43m s 1 n~
2 0.86 m s-1 :~ 0 , r I
1.26 rn s-~ ~. 0 0.1 012 0.3 0.4 015
a Slide/roll ratio,
0 I I I I 1
0 0.1 0.2 0.3 0.4 0.5
16
a Slide/roll ratio,
_ + + I i I
1~o~ " 0.088 =~
0.079
o- . ,~
12
~ 1 0.064 &
i }( 1q2o
03 oo76
o.o9o ~_
(3) ~ 0,055 ~3 O----O-- . 0.071
0.053 - 8 0.092 :-6
8
o.073 ~
~ " F+ 0.43ms 1
0050 ~ 4 " 6 I x 0.86ms 1
-S~ 6 /~ i a
Lo 1.26m5 1 & uJ
0.055
ol I I I
E 4 ~ 0.045 0 0.1 0.2 0.3 0.4 015
o Slide/roll ratio,
5
Fig 5 Circumferentially ground discs, tested at
° [iiii :!ii Po = 683, 828 and 940 M N m -z, and ~ = 0.43, 0.86
and 1.26 rn s z.. (a) at 25°C," (b) at 50°C
Fig 4 Transversely g r o u n d discs, tested at po = 683, 828 We note first that these effective friction coefficients
and 940 M N m -2, a n d 9 = 0.43, 0.86 and l . 2 6 m s t. Ixe measured in the disc machine all show a small
(a) at 25°C, " (b) at 50°C increase with load: on average a 13% increase when
the load is roughly doubled from 241 N m ~ to
459 N m- ~. On the other hand, the linearity of friction
torque with load torque in the gear tests (Figs 3(a)
The derivation of Eq (4) also assumes that the friction and (b)) suggests a coefficient of friction which is
is independent of the velocity of sliding. If this is not independent of load. However it is doubtful whether
the case, the values of p~ obtained by Eq (4) should the small changes in gradient implied by the variations
be regarded as representative (constant) values which in We found in the disc tests ( ~ 13%) would have been
would give rise to the measured energy dissipation in clearly detectable in the gear tests. Accordingly the
a complete cycle. The experiments in the disc machine average value of ~e obtained for the three loads is
(Figs 4 and 5) show that the friction rises rapidly from tabulated for direct comparison with the values
zero with increasing sliding speed to a value which is obtained from the gear tests.
fairly constant up to the maximum speed in the test. Two conclusions are immediately apparent from this
Since frictional dissipation is proportional to the comparison (Table 4):
product of friction and sliding speed, the representative
friction is weighted towards the values at high sliding (i) The mean effective friction coefficients I~
speed near to the ends of the path of contact although obtained with the transversely ground discs
this effect may be countered to some extent by the agrees closely (within 2%) with the values
(unknown) tip relief. The effect of the low friction deduced from the gear tests at all speeds and at
close to the pitch point is therefore insignificant. If both temperatures.
disc machine data could have been obtained to the (ii) The mean effective friction obtained with the
maximum slide/roll ratio experienced in the gear, it circumferentially ground discs is appreciably
would have been possible to integrate the product of higher under all conditions (23% on average)
friction and sliding speed over the range to find the than that for the transversely ground discs or
true effective value of ~ . In the event these values the gears.
have been estimated. They are indicated in Figs 4 and This latter result is in line with accepted thinking on
5 and quoted in Table 5. micro-elastohydrodynamic (EHD) lubrication. Cir-
TRIBOLOGY INTERNATIONAL
273
K. L. Johnson and D. I. Spence--Determination of gear tooth friction by disc machine
were comparable with the gear experiments rather 0.1 0.2 0.4 0.6 1.0 2.0
than at comparable rolling speeds. In view of the Roughness parameter (A)
greater scale of the disc machine, mentioned earlier, Fig 6 Friction coefficient as a function of roughness
this would have necessitated running the disc machine parameter A (= film thickness divided by combined
slower to obtain the same film thickness as achieved roughness). Circumferentially ground discs: ~ 25°C,
between the gear teeth. If, as in our experiments, the • 50°C;transverselygrounddiscs:© 25°C,• 50°C;gears:
contact pressure Po is the same for gears and discs, A 25°C, • 50°C
the Dowson-Higginson formula indicates that the film
thickness h is proportional to the product a3°-7 x 9".31
Thus, in our experiment, where ~5 was kept the same.
ground discs exhibit a much greater coefficient of
hdi.~c = (Paise)'"3= (19.()] °3 friction and show greater sensitivity to the roughness
hg~,~ \ I~gc~i;/ ~6.84/ = 1.36
parameter. It is interesting to note that extrapolations
To maintain the same film thicknesses the above of the results to higher values of A show a convergence
relationship between h, 9 and p requires that the speeds towards A ~ 3. This is consistent with previous work
should be in the ratio (a3~,,/a3o~) = (,'Pdisc/'Pgcar)-'~3/7 on the effect of roughness on traction 3' 4 which shows
= 1.6. that roughness effects become negligible at values of
A exceeding approximately 3.
A second question concerns the influence of the
variation of traction with load, revealed by the disc
tests upon the gear behaviour where, for part of the Conclusions
cycle, the load is shared by two pairs of teeth. If Measurements of tooth friction in a back-to-back gear
different friction coefficients ~ and [,.L2 are ascribed to test rig have been compared with friction measurements
contact between one pair of teeth and two pairs in a disc machine. Discs were tested which had been
respectively, the expression for lost torque becomes ground both transversely and circumferentially to
(see Appendix): approximately the same R, roughness as the gears.
Both gears and discs were tested over a comparable
range of loads and speeds, and at two temperatures
T, 2ph r, + _ [~,(L~ + L~) (25°C and 50°C).
- (2~x, - ~2)(r~ - 1)pg] (5)
• The circumferentially ground discs showed a much
For the test gear geometry this reduces to greater friction than either the transversely ground
discs or the gears (which are transversely ground).
Tf/T, = 0.143(0.091x, + 0.91tx2) (6)
It is clear from this expression that the friction Ix2, • The transversely ground discs showed a modest
when there are two pairs of teeth in contact and the increase in friction with increasing load and a modest
decrease with increasing speed. The gear tests could
sliding speed is greatest, makes the major contribution
to the overall loss. Assuming that the load is divided not resolve any variation of friction with load, but
equally between the two pairs, the contact stress in also showed a decrease with speed.
the gear tests varied from 0 to 735 MN m 2. It would
A first-order comparison of gear and disc friction
seem most appropriate, therefore, to compare the gear
at average loads and equal speeds showed good
friction results with the disc results at the lightest load
agreement (within 2%).
(Po = 683 MN m 2).
Accordingly the friction coefficients deduced from • A more detailed comparison on the basis of the
the gear tests are compared with the disc tests at roughness parameter A (film thickness divided by
Po = 683 MN m -2 in Fig 6 on the basis of roughness combined surface roughness) gave further support
parameter A. This more refined comparison supports to the conclusion that tooth friction loss can be
the earlier conclusion: that the gear tooth friction can predicted from disc machine tests provided that the
be confidently predicted from the results of the surface finish of the discs (in magnitude and
transversely ground disc tests. The circumferentially orientation) is representative of the gears.
274 October 91 Vol 24 No 5
K. L. Johnson and D. I. Spence--Determination of gear tooth friction by disc machine
Acknowledgement
T h e authors wish to a c k n o w l e d g e their debt to Mr m-- i B
G a r e t h R y d e r for his care in preparing the discs to
the prescribed surface finish.
References
1. Merritt H.E. Worm gear performance. Proc. Inst. Mech. Engrs
London, 1935, 129, 127
2. Jefferis J.J. and Johnson K.L. Sliding friction between lubricated
rollers. Proc. Inst. Mech. Engrs. London, 1968, 182, 281
3. Evans C.R. and Johnson K.L. The influence of surface roughness
on EHD traction. Proc. Inst. Mech. Engrs, London, 1980, 201,
145
4. Bair S. and Wirier W.O. Regimes of traction in concentrated
contact lubrication. Trans. ASME, Ser. F. J. Lab. Tech. 1982, Fig 7 Path o f contact A P B . T w o pairs o f teeth are in
10, 382 contact f r o m A to E and f r o m D to B, one pair f r o m
EtoD
Appendix
Friction losses in involute spur gears when one pair are in contact
The path of contact A P B is shown in Fig 7, where P
is the pitch point. I n s t a n t a n e o u s contact b e t w e e n the vc rl + r2 sec+ P I P
teeth is at C, distance x f r o m P. T w o pairs of teeth
are in contact f r o m A to E and from D to B; one pair
is in contact from E to D, where A D = EB = base × Ixl0x + Ixl
circle pitchph. W e d e n o t e A P = L~; PB = L2; E P = a; tat )
x
If L1
Ixla +
;?]I.la
X [ I J . I ( L 2 + L2~) - (21~, - P.2)p~(rc -