Non‐Newtonian thermo‐elastohydrodynamics and sub‐surface stress field of high‐performance racing spur gears

Meshing teeth pairs of involute spur gears often form the final drive of high‐performance motorsport transmissions. They are subject to high normal and shear loading. Under transient conditions pertaining to a meshing cycle, the contact conditions alter from the onset of teeth pair engagement through to maximum normal loading, followed by contact separation. Sliding motion only ceases instantaneously at the pitch point. The regime of lubrication remains mostly in non‐Newtonian thermo‐elastohydrodynamic conditions. The results show that a starved inlet boundary is attained throughout most of the meshing cycle which leads to the diminution of the pressure spike at the exit from the contact conjunction. The reversing sub‐surface shear stresses are the main source of the onset of any inelastic deformation, which is dominated by the primary pressure peak in compliance with the Hertzian maximum pressure. The shear stress field is supplemented by an induced field due to the presence of the pressure spike. Under starved conditions this secondary stress field is diminished. The combined solution of elastohydrodynamics with a thermal network model, non‐Newtonian lubricant traction, and sub‐surface stress evaluation provides for a comprehensive solution not hitherto reported in the literature.