Prediction and influencing factor analysis of gear dynamic transmission error considering micro-morphology of tooth surface and thermal deformation

WANG Youcheng; LIU Jianhua; GONG Hao; WANG Xiao

doi:10.16578/j.issn.1004.2539.2025.10.002

Abstract：[Objective]Under high-speed and heavy-load conditions,the microscopic contact deformation of gears signifi-cantly influences assembly errors and gear transmission errors.Additionally,thermomechanical deformation resulting from fric-tional heat generation on gear surfaces and convective heat transfer with the medium also significantly impacts transmission er-rors.These phenomena may render the results of traditional methods for predicting gear dynamic transmission errors inaccurate.[Methods]Firstly,the conjugate gradient method was employed to generate microtopographies of gear surfaces,establishing an accurate finite element model that accounts for rough surfaces.Transient dynamics simulations were conducted to simulate the dynamic contact processes of gears,yielding distributions of contact pressure on gear surfaces.Secondly,by discretizing the con-tact area of gear surfaces,the frictional heat flux for discrete sub-regions and the convective heat transfer coefficients for differ-ent surfaces were calculated.This approach enabled precise simulation of the steady-state temperature field during gear engage-ment.Thirdly,thermomechanical coupling simulations were performed to study the meshing process of gears.Comparisons were made of contact pressure distributions at the pitch point between gears with smooth and rough surfaces.Dynamic transmis-sion errors were calculated,taking into account microscopic contact deformation of gear surfaces and thermal deformation of gears.Lastly,a systematic study was conducted on the effects of varying surface roughness,materials'elasticity modulus,rota-tional speed,load,and lubricant temperature on gear dynamic transmission errors.[Results]The research findings show that the peak fluctuation of dynamic transmission errors,caused by a change in surface roughness from 0 to 3.2 μm,amounts to 0.013°.The peak fluctuation in dynamic transmission errors,resulting from a change in lubricant temperature from 50 ℃ to 110 ℃,is-0.011 9°.Microscopic contact deformation and thermal deformation of gear surfaces significantly affect the prediction of gear dynamic transmission errors.Under specific operating conditions,an increase in surface roughness and load shifts the dynamic transmission error curve upward,whereas an increase in lubricant temperature,materials'elasticity modulus,and rotational speed shifts the curve downward.