Experimental Tooth Contact Analysis and Life Prediction Methodology for Truck Axles Hypoid Gears

This paper describes the methodology followed for experimental prediction of tooth contact patterns of Truck Axle Hypoid Gear sets in loaded state. Effort has been made to establish Hypoid Gear Life based on Duty Cycle simulation on a pair of Test Axles an in-house developed new closed loop Axle Test Machine. Service Load Data is acquired on loaded truck to establish sustained torque levels on the Drive Axles. Loaded Tooth Contact pattern (LTCA) is generated using Gleason Program and Deflection Test analysis is carried out on the Four Square Axle Test Machine. Typical tooth contact patterns at a series of loads from no load to maximum load are generated on the axle test machine. Variation of tooth contact patterns as a function of applied torque is compared with the predicted LTCA. Methodology for accelerated testing has been concluded and correlation with the service data is being established.