بررسي اثر انحراف‌هاي ساخت بر رشد عيب حفره‌حفره‌شدن به روش تجربي

The manufacturing processes of gears are always accompanied by geometric errors due to technological complexities an‎d machining limitations. These errors can significantly affect the performance an‎d useful life of gears. This research aims to examine the impact of manufacturing-induced errors on the profiles of simple gears an‎d the role of these errors in the occurrence an‎d growth of the pitting defect. In the first step of this study, the factors influencing gear tooth failure are identified an‎d categorized. Then, the profile errors of gears are introduced, an‎d the engagement stiffness of two meshing gears is determined based on potential energy theory. Next, the engagement stiffness for gears with profile errors, including angular deviation an‎d form deviation, is calculated. A comparison of the engagement stiffness of ideal gears with that of gears possessing profile deviations indicates that the likelihood of pitting formation is higher in gears with profile errors. To validate the theoretical results, an experimental test is designed an‎d executed. In this test, a gearbox testing rig is utilized, an‎d a single-stage gearbox is subjected to load. In this gearbox, high-quality reference gears are employed to assess ideal conditions, while gears with profile deviations are used to eva‎luate the effects of geometric errors. It is noteworthy that the design of these gears is such that the pitting phenomenon is expected to occur after approximately one hundred hours of operation. The experimental results obtained indicate that the likelihood of pitting growth is greater in gears with profile errors.

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