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A Practical Approach to Gear Design and Lubrication: a Review

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A Practical Approach to Gear Design and Lubrication: a Review lubricants Review A Practical Approach to Gear Design and Lubrication: A Review Dario Croccolo 1 , Massimiliano De Agostinis 1, Giorgio Olmi 1 and Nicolò Vincenzi 2,* 1 Department of Industrial Engineering (DIN), University of Bologna, Viale del Risorgimento, 2, 40136 Bologna, Italy; [email protected] (D.C.); [email protected] (M.D.A.); [email protected] (G.O.) 2 GIULIANI, A Bucci Automations S.p.A. Division, Via Granarolo 167, 48018 Faenza, Italy * Correspondence: [email protected] Received: 9 June 2020; Accepted: 14 August 2020; Published: 20 August 2020 Abstract: The modern design of mechanical parts, such as gears, goes through the continuous demand for a high level of efficiency and reliability, as well as an increased load carrying capacity and endurance life. The aim of the present paper was to perform a review and to collect practical examples in order to provide interesting tips and guidelines for gear design, including both its dimensioning and its lubrication. From this point of view, this paper is particularly novel, as it is a full-comprehensive collection of all the tools supporting gear design. Several practical aspects have been taken into account, including the definition of the right profile shifting, the selection of a proper lubricant, and the definition of the quality grade and of the tolerances needed to obtain the correct backlash. Finally, a numerical example is provided, addressing the research of the best solution to fit a given space, while maximizing the transmittable torque over weight ratio for two mating spur gears. Keywords: gear; profile shift; gear optimization; gear tolerances; gear lubrication 1. Introduction The modern design of mechanical parts, such as gears, goes through the continuous demand for a high level of efficiency and reliability, as well as an increased load carrying capacity and endurance life. At the same time, the concepts of “robust design” and “optimization” involve nowadays the need for a very high-power density (involving smaller size, lower weight, lower noise and vibrations), as well as longer service intervals [1,2]. Finally, the aspects related to sustainability (analysis of the impact on the environment) and low-cost design are also commonly regarded as driving forces in the development of modern products. Within this framework, gear design must address, for example, low consumption of lubrication oil, keeping hydraulic losses as low as possible [3]. Oil/air mist (micro-fog) may be used for bearing and gear lubrication, especially in combination with compact design approaches, for instance in the field of machine tool industry. Regarding this point, an applicative example is shown in Figure1. A continuous lubrication can be achieved by this strategy, involving very low oil quantities with consequent consumption sharp reduction. Depending on the application, the type of oil, whose main feature is viscosity, can be selected between ISO VG32 (high speed) and ISO VG 68 (high load). The oil flow, Q [mm3/h], being needed for lubrication by micro-fog, can be evaluated by Equation (1), where Dm is the mean bearing diameter or the gear pitch diameter. Q = 1.2 Dm to 1.3 Dm (1) · · Lubricants 2020, 8, 84; doi:10.3390/lubricants8090084 www.mdpi.com/journal/lubricants Lubricants 2020, 8, x FOR PEER REVIEW 2 of 20 estimated as Q = 3000 mm3/h. The nozzles were set at 15 mm3/cycle; therefore, the number of cycles requested to the nozzles, to provide the required flow was set to 200 cycles per hour. The air pressure Lubricantsmay2020 be , 8set, 84 for this application between 0.3 and 2.0 bar, depending on the dimension of the 2 of 21 components (the bigger components, the lower the pressure level). Lubricants 2020, 8, x FOR PEER REVIEW 2 of 20 estimated as Q = 3000 mm3/h. The nozzles were set at 15 mm3/cycle; therefore, the number of cycles requested to the nozzles, to provide the required flow was set to 200 cycles per hour. The air pressure may be set for this application between 0.3 and 2.0 bar, depending on the dimension of the components (the bigger components, the lower the pressure level). (a) (b) FigureFigure 1. Example 1. Example of multi-spindleof multi-spindle head: head: geargear and bearings bearings lubricated lubricated by bymicro-fog: micro-fog: (a) drawing (a) drawing and and (b) table. (b) table. (a) WithAs reference for lubrication, to the the case selection study of inthe Figure material1, and a MOBIL its thermal DTE treatment LIGHT is 32 the oil other and key a centralizedchoice, unit,to having increasethe the power capability density: of case providing hardened (by and a nitrided suitable gears amount are the oftwo nozzles) most common 5 to alternative 30 mm3/cycle, options [4–8]. Both treatments warrant improved contact (and bending) fatigue performance. The were selected. The required oil flow, Q [mm3/h], depending on the number and size of bearings and main differences between the two treatments, from the point of view of their application, are a gears, was estimated as Q = 3000 mm3/h. The nozzles were set at 15 mm3/cycle; therefore, the number consequence of the manufacturing cycle and of( bth) e distortions arising from the thermo-chemical of cyclesprocess. requested The high to thetemperature nozzles, toof providethe carburizin the requiredg process flow induces was setlarger to 200 distortions cycles per that hour. entail The air pressuresubsequentFigure may 1. beExample machining, set for of this multi-spindle being application usually head: betweenconducted gear and 0.3 bearings by and grinding, 2.0 lubricated bar, dependingand by themicro-fog: consequent on ( thea) drawing dimension amount and of of the componentsallowance(b) table. (the to be bigger removed. components, The lower thetemperature lower the of pressurenitriding treatments level). allows for finishing process (millingAs for lubrication, or grinding) thebeing selection completed of thebefore material heat treatment, and its thermal taking advantage treatment of is lower the other distortions. key choice, to increaseHowever,As for the lubrication, nitriding power density: has the the selection drawback case hardened of ofthe generally material and nitrided requiring and its gearsthermal a longer are treatment thetreatment two mostis duration. the commonother Moreover, key alternative choice, to increase the power density: case hardened and nitrided gears are the two most common alternative optionsit produces [4–8]. Both lower treatments case depths, warrant according improved to Figure contact 2. (and bending) fatigue performance. The main options [4–8]. Both treatments warrant improved contact (and bending) fatigue performance. The differences between the two treatments, from the point of view of their application, are a consequence main differences between the two treatments, from the point of view of their application, are a of the manufacturing cycle and of the distortions arising from the thermo-chemical process. The high consequence of the manufacturing cycle and of the distortions arising from the thermo-chemical temperature of the carburizing process induces larger distortions that entail subsequent machining, process. The high temperature of the carburizing process induces larger distortions that entail beingsubsequent usually machining, conducted being by grinding, usually andconducted the consequent by grinding, amount and the of allowanceconsequent to amount be removed. of Theallowance lower temperature to be removed. of nitriding The lower treatments temperature allows of nitriding for finishing treatments process allows (milling for finishing or grinding) process being completed(milling or before grinding) heat being treatment, completed taking before advantage heat treatment, of lower taking distortions. advantage However, of lower nitriding distortions. hasthe drawbackHowever, of nitriding generally has requiring the drawback a longer of treatmentgenerally requiring duration. a Moreover, longer treatment it produces duration. lower Moreover, case depths, according to Figure2. it produces lower case depths, according to Figure 2. (a) (b) Figure 2. Depth of hardening vs time according to Bucci Automations internal standards: (a) case hardened treatment on steel 18NiCrMo5; (b) nitriding treatment on steel 41CrAlMo7. (a) (b) FigureFigure 2. 2.Depth Depth of ofhardening hardening vsvs timetime according to to Bucci Bucci Automations Automations internal internal standards: standards: (a) (casea) case hardenedhardened treatment treatment on on steel steel 18NiCrMo5;18NiCrMo5; (b) nitriding treatment treatment on on steel steel 41CrAlMo7. 41CrAlMo7. Lubricants 2020, 8, 84 3 of 21 Lubricants 2020, 8, x FOR PEER REVIEW 3 of 20 InIn the the past past 20 20 years, years, gear gear design design has has been been approached approached from from these these two two points points of of view: view: • increasing power density as much as possible, which has led to gears with asymmetric teeth, • increasing power density as much as possible, which has led to gears with asymmetric teeth, accordingaccording to to Reference Reference [ 9[9,10];,10]; and and • speeding-upspeeding-up gear gear production production time, time, which which has has led led to to additively additively manufactured manufactured gears gears [11 [11].]. • AsAs for for asymmetric asymmetric gears, gears, today, today, a modern a modern 5-axes 5-axes Computerized Computerized Numerical Numerical Control (CNC)Control machine (CNC) makesmachine it possible makes it to possible cut a tooth, to cut where
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