19FTM09.

Reduction of the Tonality of Gear Noise by Application of Topography Scattering for Ground Bevel
Gears
Author: Marcel Kasten, Christian Brecher, Christoph Löpenhaus, Andreas Lemmer, Werner Bläse, and Rolf
Schalaster
The noise behavior of transmission is mainly caused by the excitation in the gear mesh. The standardized design
and calculation methods for gears concentrate on the reduction of the excitation level. However, often the physical
noise characteristics do not conform with the human noise perception. Thus, gear design rules and guidelines are
required that are able to rate the excitation according to the perception. The effect of the targeted topography
scatter generally described is the reduction of the gear mesh amplitudes with an increase of the background
noise. In this report, the noise behavior of bevel gears is investigated with a targeted topography scattering. The
excitation and noise behavior is analyzed from the excitation in tooth contact by transmission error measurements
up to noise emission in the form of airborne noise. Finally, it is the objective to evaluate the impact of individual
topography scattering on the dynamic noise behavior. The analysis of the noise behavior of two variants are
compared regarding the difference in psychoacoustic parameters such as loudness and tonality. The potentials of
the topography deviation for the optimization of ground bevel gears in terms of tonality reduction will be shown by
test results. A test fixture for the evaluation of the operational behavior under loaded and dynamic conditions will
be used. Finally, the method is applied to a vehicle transmission and the noise behavior on the test bench and
inside of the vehicle is investigated and evaluated.
ISBN: 978-1-64353-048-2

19FTM10. Computing Gear Sliding Losses

Author: Caleb Gurd, Carlos Wink, John Bair, and Claudia Fajardo
Accurately predicting frictional losses is critical for increasing gearbox efficiency. Whereas several empirical
algorithms are available for numerically predicting coefficient of friction and gear sliding losses, a systematic
evaluation of these is necessary to establish their accuracy and range of applicability. This paper evaluates nine
different algorithms available in the literature for determining coefficient of friction and calculating gear sliding loss,
and their applicability to commercial vehicle transmissions. Power loss results are compared initially to the
experimental data from a standard FZG gear set, and then to two transmissions with helical gears for a range of
operating torque, speed, and temperature. The differences between predictions and measurements are discussed
for each algorithm evaluated and a recommendation is presented for improved accuracy within the application
range investigated. The findings of this study might help gear engineers select the appropriate algorithm for
calculating gear sliding losses, and ultimately increase gearbox efficiency.
ISBN: 978-1-64353-049-9

19FTM11. Opportunities of Efficiency Improvement by the Use of Hydro Lubricants

Author: Matthias Pfadt, Elena von Hörsten, and Balasubramaniam Vendudusamy
The majority of industrial lubricants are still based on mineral oils due primarily to low cost and good compatibility
with other oils, although different base fluid types exist in the market. However, despite their widespread use,
conventional lubricants reach functional limits in various scenarios. In addition to the limitations of natural
resources, their safe and environmentally sound handling, use and disposal often require considerable efforts. At
the same time, industrial operators’ expectations towards innovative specialty lubricants are increasing. They
range from operational and food safety to biodegradability, longer life cycles and reduced emissions and energy
consumption.
While searching for a material that meets all of these general and branch-specific requirements, water is a
visionary but yet an obvious raw material available worldwide, non-toxic, non-combustible. The benefits are clear,
but some challenges include its low viscosity, evaporation, freezing point, corrosiveness and sensitivity against
microbiological growth.
Hydro Lubricants unfold their innovative traits by using water either as a base oil or as an additive, hence the
name ‘‘Hydro Lubes’’. Initial results indicate that it is a promising technology with a great potential to deliver high
performance; some include high thermal and electric conductivity, superlow friction and good load carrying
capacity on the FZG four-square test machine. Some key challenges of Hydro Lubricants like pour point,
corrosion protection and microbiological growth have been solved by proper and advanced formulation. With the
wide range of benefits, different Hydro Lubricants have been developed for applications like gears and
hydrodynamic bearings.
Hydro Lubricants offer a more sustainable solution and are potential candidates for a wide range of industrial
applications that particularly demand for huge energy savings.
ISBN: 978-1-64353-050-5

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AGMA Publications Catalog 34 April 2020