Analysis of the load capacity limits for pitting and wear in worm gearboxes to reduce test durations

Thursday, 24 October, 2024
09:30 10:00

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Image: ©FZG

Online seminar: FVA research project 920 I

Time-consuming tests are performed to determine the wear intensity of new worm gears in order to estimate their behavior in continuous operation. If pitting damage occurs during these tests, the material breakout corrupts the wear measurements. Thus, knowledge of the formation of pitting is essential to perform these tests efficiently. Therefore, the aim of the research project was to determine the pitting load capacity limits of worm gear flanks and to quantify it as a function of the load.

A simulation model was developed within the theoretical investigations to calculate the duration of crack formation and expansion, which leads to pitting. An extensive experimental test program was also performed to determine the flank load capacity which involved determining the duration of the pitting formation phase at various torques and speeds on the test bench. This made it possible to derive a calculation rule that can be used to determine the time until pitting occurs as a function of the flank pressure. The results also show that the sliding speed can have a significant influence on the pitting load capacity. The knowledge gained could be used to develop a procedure for shortening the length of run-in tests, thus significantly reducing the test duration.