Effect of Geometric Parameters of High-Speed Helical Gears on Friction Flash Temperature and Scuffing Load Capacity in Electric Vehicles

High-speed reducers in electric vehicles, characterized by high rotation speeds, heavy loads, large helix angles, and high contact ratios, are prone to tooth surface scuffing due to high sliding speeds. This scuffing is caused by adhesion wear from excessive instantaneous friction flash temperatures. The prevailing approach to gear scuffing analysis relies on the standard formula method, which is a relatively rudimentary technique. This method lacks the precision required to accurately assess the intricate distribution of tooth surface flash temperature (TSFT), limiting its efficacy in targeted tooth optimization. This study introduces an enhanced semi-analytical method to calculate TSFT and analyzes its variation under different conditions: increased tooth number and reduced module, altered pressure angle, and varied helix angle. The aim is to understand how these geometric parameters affect TSFT and the scuffing load capacity of high-speed reducer gears. This study calculates load distribution and TSFT under peak operating conditions and shows that increasing the tooth number, pressure angle, and helix angle can reduce maximum TSFT by more than 30%, improving scuffing safety and load capacity. However, these improvements must consider the gear’s allowable bending safety factor and bearing service life. The research concludes that optimizing these geometric parameters can significantly enhance the scuffing load capacity of gearsets.