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Abstract

Gears are essential machine elements used to transmit power and motion from one unit to another under desired angular velocity ratio. Various types of gears have been developed to fulfill power transmission requirements in industrial applications. Under normal or fluctuating operating conditions, increase in fatigue load cycles, transition in lubrication regimes, fluctuating loads and speeds, etc., result in various surface fatigue wear modes which affect the performance of geared system. The severity of wear anomalies developed on gear tooth surfaces can be assessed by using vibration signals acquired from the gear box. On the other hand, reliable wear assessment is very important to perform maintenance action which depends on the sensors, data acquisition procedure, vibration signal analysis and interpretation. This paper presents results of the experimental investigations carried out to assess initiation and propagation of surface fatigue failure wear modes developed on gear tooth contact surfaces. A FZG back to back power recirculation type spur gearbox was used to conduct fatigue test experiments on spur gears under accelerated test conditions. Accelerated test conditions resulted in a rapid transition of lubrication regimes, i.e., hydrodynamic lubrication regime to boundary lubrication regime which triggered surface fatigue faults on gear tooth surfaces. A cepstral analysis method was used to assess fault severity in the geared system. The results obtained from the cepstral features were correlated to various surface fatigue faults and reduction in gear tooth stiffness. Results obtained from the experimental investigations highlighted the suitability of cepstral features to assess incipient faults developed on spur gear tooth surfaces.
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Bibliography

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2. Amarnath M., Lee S.K. (2015), Assessment of surface contact fatigue failure in a spur geared system based on the tribological and vibration parameter analysis, Measurement, 76: 32–44, doi: 10.1016/ j.measurement.2015.08.020.
3. Amarnath M., Sujatha C., Swarnamani S. (2009), Experimental studies on the effects of reduction in gear tooth stiffness and lubricant film thickness in a spur geared system, Tribology International, 42(2): 340–352, doi: 10.1016/j.triboint.2008.07.008.
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10. Lee S.K., Amarnath M. (2016), Experimental investigations to establish correlation between stribeck curve, specific film thickness and statistical parameters of vibration and sound signals in a spur gear system, Journal of Vibration and Control, 22(6): 1667–1681, doi: 10.1177/1077546314544164.
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17. Park C.S., Choi Y.C., Kim Y.H. (2013), Early fault detection in automotive ball bearings using the minimum variance cepstrum, Mechanical Systems and Signal Processing, 38(2): 534–548, doi: 10.1016/ j.ymssp.2013.02.017.
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22. Ziaran S., Darula R. (2013), Determination of the state of wear of high contact ratio gear sets by means of spectrum and cepstrum analysis, Journal of Vibration and Acoustics, 135(2): 021008, doi: 10.1115/1.4023208.
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Authors and Affiliations

Muniyappa Amarnath
1
I.R. Praveen Krishna
2
Ramalingam Krishnamurthy
3

  1. Tribology and Machine Dynamics Laboratory, Department of Mechanical Engineering, Indian Institute of Information Technology Design and Manufacturing, Jabalpur,Jabalpur 482001, India
  2. Department of Aerospace Engineering, Indian Institute of Space Science and Technology, Thiruvananthapuram – 695547, India
  3. Department of Mechanical Engineering, Indian Institute of Technology, Madras 600025, Tamilnadu, India
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Abstract

The progress of additive manufacturing technology brings about many new questions and challenges. Additive manufacturing technology allows for designing machine elements with smaller mass, but at the same time with the same stiffness and stress loading capacity. By using additive manufacturing it is possible to produce gears in the form of shell shape with infill inside. This study is carried out as an attempt to answer the question which type of infill, and with how much density, is optimal for a spur gear tooth to ensure the best stiffness and stress loading capacity. An analysis is performed using numerical finite element method. Two new infill structures are proposed: triangular infill with five different densities and topology infill designed according to the already known results for 2D cantilever topology optimization, known as Michell structures. The von Mises stress, displacements and bending stiffness are analyzed for full body gear tooth and for shell body gear tooth with above mentioned types of infill structure.

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Authors and Affiliations

A.J. Muminovic
M. Colic
E. Mesic
I. Saric
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Abstract

In the previous study, we designed one personal rescue winch for high-rise building rescue. Its key requirement is to be small and light enough to suit users. In addition to using lightweight and reasonable materials as in the proposed winch design, in this study, we proceed to optimize the weight of one two-level gear train, which accounts for a large proportion of weight. The first stage is building a weight optimization problem model with seven independent variables, establishing one optimal algorithm, and investigating the variables by Matlab software. The other is replacing the web material of the gears and pinions with Aluminum 6061-T6 and optimizing their hole diameters and hole numbers through using Ansys software. The obtained result shows a significant weight reduction. Compared to the original design, the weight reduces by 10.21% and 52.40% after the first optimal and last stages, respectively.
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Bibliography

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[10] B. Mahiddini, T. Chettibi, K. Benfriha, and A. Aoussat. Optimum design of a spur gear using a two level optimization. Mechanika, 25(4): 304–312, 2019. doi: 10.5755/j01.mech.25.4.18994.
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[14] N. Godwin Raja Ebenezer, S. Ramabalan, and S. Navaneethasanthakumar. Practical optimal design on two stage spur gears train using nature inspired algorithms. International Journal of Engineering and Advanced Technology, 8(6):4073–4081, 2019. doi: 10.35940/ijeat.F8638.088619.
[15] V. Pimpalte and S.C. Shilwant. Topology optimization of gears from two wheeler gear set using parametric study. IOSR Journal of Mechanical and Civil Engineering, 14(1):22–31, 2017. doi: 10.9790/1684-1401022231.
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[17] A.J. Muminovic, A. Muminovic, E. Mesic, I. Saric, and N. Pervan. Spur gear tooth topology optimization: finding optimal shell thickness for spur gear tooth produced using additive manufacturing. TEM Journal, 8(3):788–794, 2019. doi: 10.18421/TEM83-13.
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Authors and Affiliations

Truong Giang Duong
1
ORCID: ORCID
Van Tinh Nguyen
1
Tien Dung Nguyen
1

  1. Faculty of Mechanical Engineering, National University of Civil Engineering, Hanoi, Vietnam.
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Abstract

Polymer gears are often used in power transmission due to their numerous advantages. Heat accumulates on polymer gears during operation. Over time, this accumulated heat leads to damage; and shortens the service life of the gears. To prevent this, various fillers are added to the polymer materials. These fillers help to dissipate the heat generated on the gears. In this study, 25% glass fibers, 35% carbon powder, and 60% bronze particles were added to the polytetrafluoroethylene (PTFE) matrix to determine the wear behavior of gears. The properties of the matrix and the filler mainly influence the wear behavior of PTFE composites. The study showed that all composite gears with filler have better wear resistance than pure PTFE gears due to their better thermal stability. After the tests, it was found that the gears made of PTFE + 35% carbon additive had about 12 times better wear rates than those made of pure PTFE. Based on the average temperature values of the experiment, it was found that the mass temperature of gears made of 35% carbon-doped PTFE is about 38-39% lower than that of pure PTFE. This study contributes to the standard studies on heat build-up, thermal damage, and wear of gears made of polymers with different fillers and ratios.
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Authors and Affiliations

R. Yakut
1
ORCID: ORCID
H. Düzcükoğlu
2
ORCID: ORCID
H. Akkuş
3
ORCID: ORCID

  1. Batman University, Technology Faculty, Batman, Turkey
  2. Selçuk University, Technology Faculty, Konya, Turkey
  3. Nigde Omer Halisdemir University, Nigde Vocational School of Technical Sciences, Nigde, Turkey

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