Professional Documents
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(EASA-IM-
ti89- 154 14
CSCL 131
63/37 0 18792 1
Unclas
Prepared for the Fifth International Power Transmission and Gearhg Conference sponsored by the American Society af Mechanical Engineers Chicago, Illinois, April 25-27, 1989
Lee S. A k i n California State University Long Beach, C a l i f o r n i a 90815 and Dennis P. Townsend N a t i o n a l A e r o n a u t i c s and Space A d m i n i s t r a t i o n Lewis Research C e n t e r C l e v e l a n d , O h i o 44135
2J . -7
ABSTRACT
A p r o c e d u r e i s d e s c r i b e d t h a t was d e v e l o p e d for e v a l u a t i n g t h e wear i n a s e t o f g e a r s i n mesh under h i g h l o a d and low r o t a t i o n a l speed. The method can be used f o r any low-speed g e a r a p p l i c a t i o n , w i t h n e a r l y n e g l i g i b l e o i l f l l m t h i c k n e s s , and 1 s e s p e c i a l l y u s e f u l i n space s t e p p i n g mechanism a p p l i c a t i o n s where d e t e r m i n a t i o n o f p o i n t i n g e r r o r due t o wear i s i m p o r t a n t , such as i n l o n g l i f e sensor a n t e n n a d r i v e s . A method i s developed for t o t a l wear d e p t h a t t h e ends o f t h e l i n e o f a c t i o n u s i n g a v e r y s i m p l e f o r m u l a w i t h t h e s l i d e t o r o l l r a t i o Vs/Vr. A method i s a l s o d e v e l o p e d t h a t uses t h e wear r e s u l t s t o c a l c u l a t e t h e t r a n s m i s s i o n e r r o r a l s o known as p o i n t i n g e r r o r o f a gear mesh.
APPROACH TO SOLUTION B e f o r e d e s c r i b i n g a d e t a i l e d a n a l y t i c a l approach, i t i s n e c e s s a r y t o u n d e r s t a n d t h e background assumptions and a n a l y s i s c o n d i t i o n s assumed. F i r s t o f a l l t h e r e a r e t h r e e l u b r i c a t i o n s regimes ( P e t e r s o n . 1980) i n geared d r i v e s : ( 1 ) Boundary ( a l l a s p e r i t y c o n t a c t - n o f i l m ) , ( 2 ) mixed, and ( 3 ) f u l l f i l m ( n o a s p e r i t y c o n t a c t ) . T h i s paper w i l l d e a l w i t h wear i n t h e boundary l u b r i c a t i o n r e g i m e o n l y . Wear i n t h e f u l l f i l m l u b r i c a t i o n regime i s n e g l i g i b l e . Second I t i s presumed t h a t p e o p l e d e s i g n i n g g e a r s f o r space a p p l i c a t i o n s w i l l have a gear d e s i g n computer program f r o m w h i c h parameters can be p u l l e d f o r use i n t h e a n a l y s i s p r e s e n t e d h e r e i n . T h i s saves c o n s i d e r a b l e t i m e and a l l o w s use o f t h e s i m p l i f i e d method p r e s e n t e d a t t h e end o f t h i s p a p e r . The c o n v e n t i o n a l approach t o wear ( D u d l e y , 1962 and A k i n , 1973) i s t o c o n s i d e r t h a t wear can c o n s i s t o f one o r more o f t h e f o l l o w i n g modes ( 1 ) l o w speed l u b r i c a t e d wear, ( 2 ) p i t t i n g i n i t i a t e d wear, ( 3 ) a b r a s l v e wear, and ( 4 ) s c u f f i n g o r s c o r i n g t h a t my e v e n t u a l l y l e a d t o s e i z u r e . O n l y l u b r i c a t e d l o w speed a d h e s i v e wear i s c o n s i d e r e d i n t h i s p a p e r . The s e c t i o n s t o f o l l o w p r o v i d e a q u a n t i t a t i v e a n a l y s i s o f low speed a d h e s i v e wear i n g e a r s . A l t h o u g h s p u r g e a r s a r e used h e r e as t h e example case, t h e method p r e s e n t e d would be a p p l i c a b l e t o o t h e r t y p e s of g e a r s . DEVELOPMENT OF THE THEORY The boundary l u b r i c a t i o n r e g i m e i s d e f i n e d q u a n t i t a t i v e l y as g e a r s o p e r a t i n g a t a speed and l u b r i c a n t v i s c o s i t y such t h a t t h e lambda r a t i o ( A ) i s l e s s t h a n 0 . 4 ( 0 < X 5 0 . 4 ) where:
n a .
l
1
INTRODUCTION Gears used i n space a p p l i c a t i o n s a r e u s u a l l y t h o u g h t o f as " i n s t r u m e n t g e a r s " w i t h n e g l i g i b l e l o a d t h a t must m a i n t a i n p o s i t i o n a c c u r a c y t h r o u g h o u t t h e i r o p e r a t i o n a l l i f e o r as d e p l o y m e n t l a c t u a t o r g e a r s t h a t may have i n e r t i a l l o a d s b u t a v e r y low number o f d u t y cycles. More and more f r e q u e n t l y t h e combined i n s t r u m e n t / power d r i v e s a r e emerging o n t h e space mechanisms scheme such as d r i v e s f o r weather s a t e l l i t e s where p o i n t i n g a c c u r a c y (as i n i n s t r u m e n t s ) as w e l l as s u b s t a n t i a l i n e r t i a l l o a d a r e imposed due t o momentum compensated a n t e n n a s . T h i s t y p e of d r i v e may a l s o have a c o n t i n u o u s d u t y c y c l e f o r up t o 10 y e a r s . Such d r i v e s c a n n o t be c o r r e c t e d b y use of a n t i - b a c k l a s h d e v i c e s because t h i s c o n t r i b u t e s t o more wear as a r e s u l t o f t h e a d d i t i o n a l a n t i - b a c k l a s h d e v i c e l o a d i n g s p r i n g s . Also " p o s i t i o n a c c u r a c y " i s n o t c o r r e c t e d b y such d e v i c e s t h a t a r e s t i l l s u b j e c t e d t o s e v e r e wear. A g e a r arrangement must be d e v i s e d t h a t w i l l m i n i m i z e wear e f f e c t s due t o g e a r r a t i o and p r o v i d e addendum m o d i f i c a t i o n t h a t w i l l m i n i m i z e t h e t o o t h wear r a t e . T h i s paper d e s c r i b e s a method t h a t has been developed f o r a n a l y z i n g t h e t o t a l g e a r t o o t h wear and i t s e f f e c t on p o i n t i n g a c c u r a c y . The r e s u l t s can a l s o be used t o a n a l y z e t h e r e s u l t i n g e f f e c t on g e a r dynamic l o a d i n g .
x=
This a l l o w s in t e r a c t i o n Real i z i s due t o s F i g . 1, t h e
(1)
s l i d i n g ) and t h e compressive s t r e s s must be c a l c u l a t e d . The n e c e s s a r y f o r m u l a s may be f o u n d i n Gay (1970) and o t h e r references. to determine the s l i d i n g distance per pass a t any p o i n t on t h e t o o t h p r o f i l e . The A r c h a r d wear e q u a t i o n ( R a b i n o w i c z , 1965) w i l l be used t o c a l c u l a t e d e p t h wear ( h ) as f o l l o w s KWNX h = 3PAa where
K WN
where
P
p =
+
P
=
r e l a t i v e radius of curvature
pP
p9
X p
A ,
= face w i d t h gear
=
E'
and when
El = E2:
E'
E1
E2
E/2
(for s t e e l g e a r s o n l y )
(6)
E
where
w _T - N - Rb - R
where Rb
R
I
cos @
(3)
sC =
0 . 3 5 WNE' 1 / 2
Fp
=
c o m p r e s s i v e s t r e s s (AGMA.
1982)
5s
bC Y
b F = Herzian c o n t a c t area
(7)
(4),
Vs Vr
p
w
sin
Vr2 = s l i d i n g v e l o c i t y
wp = r o l l i n g v e l o c i t y
$1 = r a d i u s o f c u r v a t u r e a t p o i n t
so t h a t t h e
b's
can be c a n c e l l e d
'
$i b Cy
(8)
,I
wear on t h e p i n i o n must be added t o t h e wear on t h e gear t o o b t a i n t h e t o t a l wear a t a s p e c i f i c p o i n t on the l i n e o f a c t i o n . Thus, i f we o b s e r v e i n Eq. (8) t h a t t h e grouped parameters
or el =
-degrees,
nRb
180 Chl
and
(12)
F : i
e5 =
t h e t o t a l wear can be f o r m u l a t e d a s :
KWN
-rad Eh5
Rb
or
Vss2Cy2) (9) e5
F u r t h e r , t h e c o n t a c t c y c l e s f o r t h e p i n i o n can be c a l c u l a t e d from:
gear r a t i o .
Thus: at
Ehl =
-g#
KWNC 2
(mgVsspl
Vssgl)l
&
+ Vss92)5
a t OD o f p i n i o n .
The t a s k now i s t o b a l a n c e t h e wear a t t h e extreme ends o f t h e l i n e o f a c t i o n (see F i g . 2) so t h a t Ehl = Ehg. T h i s can be a c c o m p l i s h e d by a d j u s t i n g t h e addendum o f t h e p i n i o n and g e a r on s t a n d a r d c e n t e r s . Thus Aap = -hag i s a d j u s t e d u n t i l :
EV1= ( m g V ssp1+ v s s g l ) l = (mgVSsp2+ vssg2)5= Ev5
pd
d and
N +2+AN * 'd
Do=
el=
' 3
Eh,
rad
Ihl= h p l
hgl
3pF ( V s s l C y l
-degrees, so
nRb e5
180 Lh5
t h a t by d e s i g n
(13)
el
OD of g e a r , and
Let Diametral P i t c h Pd
I
48 Np = 24
41
= 20"
Ng = 120
Rb = 1.1746
(10)
Gear r a t i o = 5 Addendum m o d i f i c a t i o n
ANp = -ANg = 0
do = 0.54166 Do = 2.54166
(5x.4386 13.0623 1 2 . 9 7 4 4
a c o n s i d e r a b l e mismatch r e s u l t s h e r e . The p o i n t i n g e r r o r s due t o wear t h a t r e s u l t h e r e would be (from Eas. ( 1 2 ) and ( 1 3 ) ) : KW C el = Zhl/Rb where Ehl 3 1 3PF
o.02491
e5 = Eh5/Rb
(11)
where
h5
-e
KW C
CV5
0.005671
e5 = 0.005671/1.1746
= 0.0048 r a d . or 0.28O
1
I
~
a l s o t h e t o p l a n d o f t h e p i n i o n would have been reduced from 0.0144 t o 0.0109 and worse t h e p i n i o n root (LPC) would have been reduced by wear 0.0236 i n . ( 6 6 p e r c e n t ) of the t o o t h thickness. A f t e r several i t e r a t i o n s the f i n a l design r e s u l t e d . L e t : Np = 24, Ng = 120, ANp = 0.96, ANg = -0.96 Outside diameter of p i n i o n do = 0.561666
=
d e t e r m i n e t h a t c a l c u l a t e d wear d e p t h h o v e r 3 y e a r s i s 0.049 i n . Thus t h e p r e d i c t e d wear l i f e w i l l be 0.0023/0.0049 x 3 y e a r s = 1 . 4 y e a r s or 16.9 m n t h s . Since t h i s i s l e s s than i s desired, a design modificat i o n would be n e c e s s a r y . I t s h o u l d a l s o be n o t e d t h a t t h e c h o i c e o f gear arrangement can a l s o be v e r y i m p o r t a n t i n m i n i m i z i n g g e a r d r i v e p o i n t i n g e r r o r . b u t t h i s i s beyond t h e scope of t h i s paper. CLOSURE The b a s i c t o o l s have been p r o v i d e d i n t h i s paper f o r t h e m i n f m i z a t i o n of p o i n t i n g e r r o r due t o wear t h r o u g h m o d i f i c a t i o n of s t a n d a r d gear t o o t h geometry, a l s o an example has been p r o v i d e d t o c l e a r l y i l l u s t r a t e t h e use o f t h e method. T h i s method i s e a s i l y adapted t o o t h e r t y p e s o f g e a r s u s i n g t h e same p r i n c i p l e s . T h i s i s a f i r s t a t t e m p t a t q u a n t i z a t i o n o f gear wear and e s p e c i a l l y i t s e f f e c t on g e a r l i f e i n terms o f an a l l o w a b l e p o i n t i n g inaccuracy. REFERENCES
AGMA, 1982, " R a t i n g t h e P i t t i n g R e s i s t a n c e and Bending S t r e n g t h of Spur and H e l i c a l I n v o l u t e Gear Teeth," S t a n d a r d 218.01, American Gear M a n u f a c t u r e r s A s s o c i a t i o n , A l e x a n d r i a , VA. A k i n . L.S., 1973. "EHD L u b r i c a n t F i l m T h i c k n e s s Formulas f o r Power T r a n s m i s s i o n Gears."-ASME Paper 73-LUB-21. Dudley, D.W., 1962, Gear Handbook. McGraw H i l l , New
O u t s i d e d i a m e t e r o f gear
Do
2.521666
+ 0.4021)
LV5
(5x.5332
+ 1-1.14221)2
e l = 0.00718/1.1746 = 0.00611 r a d , or 0.350" e5 = 0.00726/1.1746 = 0.0618 r a d , o r 0.354" This i s a substantial reduction i n p o i n t i n t e r r o r e l caused by wear f r o m t h e o r i g i n a l s t a n d a r d gear des ign . I t s h o u l d be n o t e d h e r e t h a t t h e above e r r o r s e l and e5 a r e due t o wear o n l y and m u s t be added t o t h e o r i g i n a l b a s i c e r r o r due t o b a c k l a s h and t o o t h - t o - t o o t h composite e r r o r s t o g e t a t o t a l p o i n t i n g e r r o r a t t h e end o f l i f e a f t e r C y l and Cy2 c y c l e s o f t h e p i n i o n and g e a r r e s p e c t i v e l y . The gear wear l i f e can be t h e c r i t i c a l f a i l u r e c r i t e r i a . A s an example. c o n s i d e r an i n s t r u m e n t t h a t i s c o n s i d e r e d i n o p e r a b l e i f i t s p o i n t i n g e r r o r exceeds 0.2". W would c a l c u l a t e i t s l i f e as f o l l o w s . L e t ' s e say t h e d e s i r e d l i f e i s 15 000 000 c y c l e s ( C ) o v e r t h r e e y e a r s and we d e t e r m i n e t h a t a l l o w a b l e g a c k l a s h i s ea = 0 . 2 "
I
n/180
x
Rb
ea = 0.00349
York. Dudley, D . W . , 1954, P r a c t i c a l Gear Desiqn, McGraw H i l l , New York. Dudley, D . W . , 1984, Handbook of P r a c t i c a l Gear Design, McGraw H i l l , New York. Gay, C . E . . 1970, How t o D e s i g n t o M i n i m i z e Wear i n Gears, Machine D e s i g n , Vol. 42. No. 29, Nov. 26, DD. 92-97. K h i r a i l a . T.W., 1976, On t h e Geometry o f E x t e r n a l I n v o l u t e Spur Gears, T.W. K h i r a l l a , N o r t h H o l l y w o o d , CA. P e t e r s o n , M.B. and Winer, W.O., 1980, Wear C o n t r o l Handbook, ASME. New York. R a b i n o w i c z , E . , 1965, F r i c t i o n and Wear o f M a t e r i a l s , John W i l e y & Sons, New Y o r k .
TABLE I.- COMPUTER PRINTOUT FOR SLIDING AND HERTZ STRESS AT 5 POINTS ON THE TOOTH PROFILE L o c a t i o n on tooth p r o f i l e (a) Rolling velocity, in./s Sliding velocity, in./s Hertzian S p e c i f ic sliding ratio
-3.01 -0.64
-0.00
3.01 0.64
0.00
0.7118 0.1670
0.0000
-0.0560 -0.7814
0.21 2.58
-0.21 -2.58
0.4386
TABLE 11. - COMPUTER PRINTOUT FOR SLIDING AND HERTZ STRESS A T 5 POINTS ON THE TOOTH CONTACT L o c a t i o n on t o o t h p r o f i1 e (a) Roll angle,
c,
S 1 id i ng veloci t y , in./s
Hertzian stress, 1 by i n .
sliding ratio
"ssl
0
51 988 44 858 47 710 16 479
-0.6725 0.0892
-0.0000
-0.00
1.61 3.58
-1.61 -3.58
0.3177 0.5332
DISTANCE
I
ALI ION
Space Administration
''
Report
I
I
AVSCOM TR-88-C-033
4. Title and Subtitle
z.
Laovernrnen
5. Report Date
7 . Author(@
E4532
10. Work Unit No.
NASA Lewis Research Center Cleveland, Ohio 44135-3191 and Propulsion Directorate U.S. Army Aviation Research and Technology Activity-AVSCOM Cleveland, Ohio 44135-3127
12. Sponsoring Agency Name and Address
505-63-5 1 1L 1622mA47A
11. Contract or Grant No.
Technical Memorandum
14. Sponsoring Agency Code
National Aeronautics and Space Administration Washington, D.C. 20546-0001 and U.S. Army Aviation Systems Command St. Louis, Mo. 63120-1798
15. Supplementary Notes
Prepared for the Fifth International Power Transmission and Gearing Conference sponsored by the American Society of Mechanical Engineers, Chicago, Illinois, April 25-27, 1989. Lee S. Akin, California State University, Long Beach, California 90815 (work funded under Grant NAG3-20) and Dennis P. Townsend, NASA Lewis Research Center.
16. Abstract
A procedure is described that was developed for evaluating the wear in a set of gears in mesh under high load and low rotational speed. The method can be used for any low-speed gear application, with nearly negligible oil film thickness, and is especially useful in space stepping mechanism applications where determination of pointing error due to wear is important, such as in long life sensor antenna drives. A method is developed for total wear depth at the ends of the line of action using a very simple formula with the slide to roll ratio V,/V,. A method is also developed that uses the wear results to calculate the transmission error also known as pointing error of a gear mesh.
21. No of pages
22. Price'
Unclassified
I
Unclassified
I
8
I
A02
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