Hypoid gear integrated wear model and experimental verification design and test

Hypoid gear abrasive wear significantly influences transmission error which may worsen gearing performance. Wear and transmission error are best studied jointly. This paper reports on a proposed integrated hypoid gear wear model which combines Archard's wear equation with a conjugate approach, tooth contact analysis. Transmission error calculation is included in this integrated wear model. The model is also tested and verified by an experimental design in which transmission error measures wear rate. This allows hypoid gear wear prediction simulation to be controlled by transmission error. It can be examined, calibrated, and synchronized with solid hypoid gear wear progress. Identical no-wear and used some-wear vehicle hypoid gears with different wear times are applied experimentally. Statistical analysis standard deviations and geometric means are used to quantify transmission error magnitude and fluctuation. Magnitude controls wear prediction geometry updates. Fluctuation examines integrated wear model accuracy by comparing transmission errors. The test suggests that the accuracy of this integrated hypoid gear wear model is acceptable as there is minimal difference between predicted gear wear and actual gear wear.