An Effective Method for Identifying Uneven Load Distribution on the Tooth Faces of Misaligned Wide-Faced Helical Gear Pairs

Wide-faced helical gears are commonly used in ships and industrial applications, where high torque transmission is required. These gears are highly sensitive to shaft misalignment, which can alter the load distribution across a gear pair, leading to increased contact stress and tooth root stress (TRS). In this study, the finite element method is employed to analyze the relationship between load distribution on the tooth face and TRS distribution at various positions under different misalignment errors (MEs). It was ultimately determined that the TRS distribution through the tooth slot center reflects the contact state of the tooth face, and through quantitative analysis, reveals the relationship between ME and the degree of load distribution unevenness, establishing a method to identify the degree of load distribution unevenness on the tooth face by the TRS distribution through the center of the tooth slot. Finally, a new strain gauge arrangement method is proposed and experimentally validated. This method effectively captures the TRS of wide-faced helical gears with misalignment and pitch errors, thereby obtaining a more accurate TRS distribution at the center of the tooth slot.