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During the past 10 years, the PM industry has put a lot of focus on how to make powder metal gears for automotive transmissions a reality. To reach this goal, several hurdles had to be overcome, such as fatigue data generation on gears, verification of calculation methods, production technology, materials development, heat treatment recipes, design development, and cost studies.
All of these advancements will be discussed, and a number of vehicles with powder metal gears in their
transmissions will be presented. How the transmissions have been redesigned in order to achieve the required stress levels while minimizing weight and inertia, thus increasing efficiency, will also be discussed.
One of our goals at Power Transmission Engineering is to help you understand, identify and select the best technology for your mechanical power transmission or motion control applications. With every project, you have to decide which components to use, and which suppliers, based on functionality, quality and price. We aim to help you make those decisions informed by providing the latest information on current technology, especially when it comes to mechanical components.
This paper provides a mathematical framework and its implementation for calculating the tooth geometry of
arbitrary gear types, based on the basic law of gear kinematics. The rack or gear geometry can be generated
in two different ways: by calculating the conjugate geometry and the line of contact of a gear to the given
geometric shape of a known geometry (e.g., a cutting hob), or by prescribing the surface of action of two gears in contact and calculating the correspondent flank shapes.
A thermo-mechanical model of a splash lubricated one-stage gear unit is presented. This system corresponds to a first step towards the design of a hybrid vehicle gearbox that can operate up to 40,000 rpm on its primary shaft. The numerical model is based on the thermal network method and takes into account power losses due to teeth friction, rolling-elements bearings and oil churning. Some calculations underline that oil churning causes a high amount of power loss. A simple method to reduce this source of power losses is presented, and its influence on the gear unit efficiency and its thermal capacity is computed.
In this paper, the influences of various gear parameters on the mesh stiffness are systematically investigated by using the finite element method. The comprehensive analysis shows that contact ratios are the key factors affecting the fluctuation value of mesh stiffness.
This paper presents a physically grounded calculation method to determine the
efficiency of worm gear drives. This computation is based on the Institute of Machine
Elements, Gears, and Transmissions (MEGT) tribological simulation, which can determine the local tooth friction coefficients (Ref. 1). With this knowledge other power losses such
as the bearings, oil churnings and seals power losses can also be calculated.