High Power Density Gears Using a Systems Engineering Approach for Selection, Test, and Evaluations of Emerging Materials, Surface Engineering, and Tri

Test methods for scuffing and fatigue are available to assess surface technologies for high power density gears. Five key tribology parameters are identified to link mechanistic failure processes with engineering design parameters. The evaluation of advanced gear material processes, surface finishing and surface treatments, like laser peening, are proposed. The purpose is to selectively use certain treatments to enhance scuffing and fatigue in the precise areas where they are needed. New oil formulations are proposed for run-in with lower friction and for emergency oil-out lubrication condition. Simulated gear contact testing will be conducted to select potential surface enhancement technologies for process development. Surface enhanced gears are a deliverable for Phase III testing and commercialization. A new rolling/sliding contact fatigue rig for micro-pitting is proposed for more relevant testing for high power density gear technology.