The Development and Experimental Validation of a Real-Time Coupled Gear Wear Prediction Model Considering Initial Surface Topography, Dynamics, and Thermal Deformation

Errors affect the actual meshing process of gears, alter the actual wear pattern of the tooth profile, and may even impact the overall service life of machinery. While existing research predominantly focuses on individual errors or a narrow set of factors, this study explores the combined effects of multiple errors on tooth profile wear. A comprehensive gear wear prediction model was developed, integrating the slice method, lumped mass method, Hertz contact model, and Archard’s wear theory. This model accounts for initial tooth surface topography, thermal deformation, dynamic effects, and wear, establishing strong correlations between gear wear prediction and key factors such as tooth surface morphology, temperature, and vibration. Experimental validation demonstrated the model’s high accuracy, with relatively small deviations from the observed wear. Initial profile errors (IPEs) at different positions along the tooth width result in varying relative sliding distances, leading to differences in wear depth despite a consistent overall trend. Notably, large IPEs at the dedendum and addendum can influence wear progression, either accelerating or decelerating the wear process over time.