Study on the tooth surface wear characteristics of helical gears under mixed elastohydrodynamic lubrication

Existing research on tooth surface wear of helical gears has insufficiently considered the complex and variable lubrication conditions between meshing tooth surfaces. This study constructed a mixed elastohydrodynamic lubrication (EHL) model based on the meshing characteristics of helical gears, analyzed the lubrication characteristics between the meshing tooth surfaces and the temperature changes induced by asperity contact and oil film shear, and introduced them into the improved Archard wear model to construct the surface wear calculation model under the mixed EHL conditions. Taking the changes in meshing characteristics of tooth profile during the tooth surface wear accumulation process as a connecting bridge, the mutual influence relationships among the tooth surface wear, lubrication characteristics, and tooth surface temperature rise were systematically clarified. The cumulative distribution law of tooth surface wear and the influence of tooth surface roughness, working conditions, and tooth profile parameters on the tooth surface wear depth were explored. The research indicates that the wear depth at the tooth root and top is deeper than that at the pitch position, the pinion's surface wear depth is greater than that of the gear, and the maximum wear appears at the pinion's tooth root. The wear depth under mixed EHL conditions is nearly 4 orders of magnitude lower than that under dry friction conditions. Reducing the magnitude of tooth surface roughness can effectively decrease the tooth surface wear depth. Appropriately increasing the velocity, module, tooth width, helix angle and tooth surface hardness is beneficial to improving the anti-wear ability of tooth surfaces. This study can provide a reliable theoretical basis for predicting and optimizing the tooth surface wear of helical gears under complex lubrication conditions.