Wear prediction and characterization of steel and copper alloy spur gears

Whilst computer modeling and analysis have achieved significant strides in recent years, experimental studies are still essential to evaluate mechanical components that are susceptible to deterioration. As one of the most crucial parts in every sector, gears are required to wear studies using variable torque and speed in a dry or lubricated state to estimate gear life. The target of this study was to apply analytical techniques to find the involute tooth spur gear wear depth, which was subsequently confirmed by experimental findings. Under dry operating parameters, a coordinate measuring machine (CMM) is employed to analyze variations in the angular motion of worn-out spur gears. The two-surface observation method (TSOM) was applied to calculate the sliding distance of the mated gear flank surfaces. A quantitative formula for wear on involute spur gear was constructed using the wear rate curve produced from pin-on-disc experimental data. Investigating the wear track involved using SEM-EDAX analysis and a non-contact mode surface profilometer. The predicted gear and pinion wear depth have been validated by experimental testing. The wear model applied in this study gives an approximate relationship between sliding distance and the product of wear rate and total sliding distance.