OIL-SEAL GAS FLOW r SLAVE-SYSTEM OIL INLET Table 1
r DRIVE M I N E R A L - O I L T E S T LUBRICANT
', SHAFT
LOADING VANE
L
TEST-LUBRICANT
OUTLET TEMPERATURE ~ \ y /
MEASUREMENT LOCATION ^ ^
Fig. 5 NASA-Lewis Research Center's spur gear fatigue test apparatus
fTEST
/ / GEARS
r SLAVE GEAR ^ D R|VE SHAFT
/ r BELT PULLEY
H , „ L O A D I N G ^ , TORQUE
b H f l H
VANE^ -
VIEW A - A
Fig. 6 Schematic diagram of spur gear fatigue apparatus
fiber-glass filter. The test lubricant can be heated electrically with
an immersion heater. The skin temperature of the heater is con-
trolled to prevent overheating the test lubricant.
A vibration transducer mounted on the gearbox is used to auto-
matically shut off the test rig when a gear-surface fatigue occurs.
The gearbox is also automatically shut off if there is a loss of oil
flow to either the main gearbox or the test gears, if the test gear oil
overheats, or if there is a loss of seal gas pressurization.
The test rig is belt driven and can be operated at several fixed
speeds by changing pulleys. The operating speed for the tests re-
ported herein was 10,000 rpm.
Test Lubricant. All tests were conducted with a single batch
of super-refined naphthenic mineral oil lubricant having proprie-
tary additives (antiwear, antitoxidant, and antifoam). The physi-
cal properties of this lubricant are summarized in Table 1. Five
percent of an extreme pressure additive, designated Anglamol 81
(partial chemical analysis given in Table 2), was added to the lu-
bricant. The lubricant flow rate was held constant at 800 cm 3 /min,
and lubrication was supplied to the inlet mesh of the gear set by jet
lubrication. The lubricant inlet temperature was constant at 319 ±
6 K (115° ± 10° F), and the lubricant outlet temperature was near-
ly constant at 350 ± 3 K (170° ± 5° F). This outlet temperature
was measured at the outlet of the test-gear cover. A nitrogen cover
gas was used throughput the test as a baseline condition, allowing
testing at the same conditions at much higher temperatures with-
out oil degradation. This cover gas also reduced the effect of the oil
additives on the gear surface boundary lubrication by reducing the
Journal of Lubrication Technology
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Properties of super-refined naphthenlc, mlnsral-oll test lubricant
Kinematic v i s c o s i t y , c m / s e c (cS), at
SHAFT
266 K ( 2 0 ° F) 2812X10" 2 (2812)
OIL
311 K ( 1 0 0 ° F) 73X10" 2 (73)
SEAL?
372 K (210° F) 7. 7X10" 2 (7. 7)
477 K (400° F) 1. 6 x l O " 2 (1. 6)
F l a s h point, K ( ° F ) 489 (420)
Autoignition t e m p e r a t u r e , K ( ° F ) 664 (735)
P o u r point, K ( ° F ) 236 (-35)
Density at 289 K ( 6 0 ° F ) , g / c m 3 0. 8899
Vapor p r e s s u r e at 311 K ( 1 0 0 ° F), m m Hg ( o r t o r r ) 0.01
i
PRESSURE T h e r m a l conductivity at 311 K ( 1 0 0 ° F), J / ( m ) ( s e c ) ( K ) ( B t u / ( h r ) ( f t ) ( ° F ) ) . . . 0 . 0 4 ( 0 . 0 7 2 5 )
Specitic heat at 311 K ( 1 0 0 ° F ) , J/(kg)(K) (Btu/(lb)(°F)) 582(0.450)
Table 2 Properties of lubricant additive Anglamol 8 1
Percent p h o s p h o r o u s b y weight 0.66
Percent sulfur b y weight 13.41
Specific gravity 0.982
rn-1112415 K i n e m a t i c viscosity a t 3 7 2 K ( 2 1 0 ° F ) ,
c m 2 / s (cS) 29.5 X 1 0 - 2 (29.5)
Table 3 Chemical composition of Var AISI 9310
gear material by percent weight
Element C MN SI NI CR MO CU P&S
Weight 0.10 0.63 0.27 3.22 1.21 0.12 0.13 0.005
percent
SLAVE-GEAR
chemical reactivity of the additive-metal system by excluding oxy-
gen [27].
Test Gears. Test gears were manufactured from vacuum arc
remelted (VAR) AISI 9310 case carburized steel to an effective
case depth of 1 mm (0.040 in.). T h e material chemical composition
is given in Table 3 and the heat treatment schedule is given in
Table 4. The nominal Rockwell C hardnesses of the case and core
were 62 and 45, respectively. This material is a commonly used
steel in gear manufacture.
CD-11421-15
Photomicrographs of the microstructure of the AISI 9310 are
shown in Fig. 7. Fig. 1(a) shows the high-carbon fine grained mar-
tensitic structure of the hardened case of the gear. Fig. 1(b) shows
the core region of the gear with its softer low-carbon refined aus-
tenitic grain structure.
Dimensions for the test gears are given in Table 5. All gears have
a nominal surface finish on the tooth face of 0.406 iim (16 /un.) rms
and a standard 20 deg involute tooth profile.
Test Procedure. T h e test gears were cleaned to remove the
preservative and then assembled on the test rig. T h e test gears
were run in an offset condition with a 0.30-cm (0.120-in.) tooth-
surface overlap to give a load surface on the gear face of 0.28 cm
(0.110 in.) of the 0.635-cm (0.250-in.) wide gear, thereby allowing
for edge radius of the gear teeth. By testing both faces of the gears,
a total of four fatigue tests could be run for each set of gears. All
tests were run-in at a load of 1157 N/cm (661 lb/in.) for 1 hr. The
load was then increased to 5784 N/cm (3305 lb/in.) with a 1.71 X
109 N / m 2 (248,000 psi) pitch-line Hertz stress. At the pitch-line
load the tooth bending stress was 24.8 X 108 N/m 2 (35,100 psi) if
plain bending is assumed. However, because there is an offset load
there is an additional stress imposed on the tooth bending stress.
Combining the bending and torsional moments gives a maximum
stress of 26.7 X 108 N/m 2 (38,100 psi). This bending stress does not
consider the effects of tip relief, which will also increase the bend-
ing stress.
The test gears were operated at 10,000 rpm, which gave a pitch-
line velocity of 46.55 m/s (9163 ft/min). Lubricant was supplied to
the inlet mesh at 800 cm 3 /min (0.21 gal/min) at 319 ± 6 K (115° ±
10° F). The tests were continued 24 hr a day until they were shut
down automatically by the vibration-detection transducer located
on the gearbox, adjacent to the test gears. The lubricant was circu-
APRIL 1976 / 271