Gear mechanisms are widely used as power and motion transmission components in many areas of the industry. The efficiency of gears is especially important in high power transmission. On the other hand, maintaining tooth strength is equally important, particularly under high torque loads. In gear mechanisms, manufacturing, tolerance, assembling, axial misalignments and surface errors occur. Effects such as overloading and deformations in the shafts also disrupt the law of gearing, increase friction resistance, noise and wear, and reduce the efficiency and service life. In addition to this, distortion of tooth profiles can occur in gears which have high gear ratio.
In this study, an optimization was carried out to minimize the above-mentioned drawbacks of the high gear ratio involute profile gear mechanism. In the application part of the study, a train gearbox designed to be driven by an electric motor was taken as reference and the gear pair was modeled and analyzed in KISSsoft software. Micro geometry optimization was performed for the gearbox consisting of single-stage helical gear set with a gear ratio of 7.056 and the results were compared. Transmission errors of the gear pair have been minimized with micro modifications. Here, linear tooth tip relief(Cαa) and lead crowning(Cβ) modifications have been applied to reduce the peak-to-peak transmission error for the gear pair. The macro properties of the gears were kept constant, and the linear tooth tip relief and lead crowning amounts were determined as minimum 0 and maximum 30 μm for the first stage of optimization process. The optimum gear pair was selected, and their the peak-to-peak transmission error decreased by 47.3% compared to the first case, while the noise level of the gear pair decreased by 7% and the power loss decreased by 16% compared to the case without micro geometry modifications. ORCID NO: 0009-0007-7892-1378
Anahtar Kelimeler: Helical Gear, Micro Geometry Optimization, Gear Profile Modification, KISSsoft
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