In this study, an automatic simulation method for analyzing the efficiency and heat balance of various designs of worm gears is developed and integrated in WTplus. The current version of WTplus can analyze gearbox systems containing cylindrical and bevel gears. A suitable abstraction of the gearbox system by nodal points forms the basis for an efficient and accurate calculation of local component temperatures. The subsequent calculation of the heat balance of the gearbox is based on the so-called “Thermal Network Method†(TNM) (Refs. 11, 15), which is a mathematical method for determining the heat transfer between single components, as well as the heat dissipation to the environment. The efficiency is based on the power loss calculation of gears, bearings, seals and other rotating elements. The simulation program WTplus (Ref. 16) has been developed to investigate the efficiency and heat balance of gearbox systems.
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Therefore, the prediction of the heat balance and component temperatures of gearboxes containing one or more worm gear stages is very important, especially during the design phase. Due to their high power density and sliding speeds within the tooth contact, frictional heat and thermal stresses are higher compared to helical, bevel and hypoid gears, and thus the thermal load capacity of worm gears is lower (Ref. 24). If torque conversion with high gear ratio, compact installation space and 90-degree axis-crossing angle is needed, often worm gears are used.
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