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CHAPTER GEARS AND SPLINES 8.0 TABLE OF CONTENTS 8.1 INTRODUCTION 1 8.2 GEAR DESIGNS 2 8.3 GEAR AND SPLINE FAILURE MODES 6 8.3.1 Wear 6 8.3.2 Surface Fatigue 6 8.3.3 Plastic Flow 7 8.3.4 Breakage 8 8.4 GEAR RELIABILITY PREDICTION 8 8.4.1 Velocity Multiplying Factor 9 8.4.2 Gear Loading Multiplying Factor 9 8.4.3 Misalignment Multiplying Factor 10 8.4.4 Lubricant Multiplying Factor 11 8.4.5 Temperature Multiplying Factor 11 8.4.6 AGMA Multiplying Factor 12 8.5 SPLINE RELIABILITY PREDICTION 12 8.6 REFERENCES 19 8.1 INTRODUCTION The reliability of a gear along with the other gearbox components is an extremely important consideration in the design of any power-transmission system, ensuring that the required loads can be handled over the intended life of the system. Some general design constraints and requirements need to be given special attention because of their potential impact on the long-term reliability of the total system. One is the operating power spectrum and determining the potential requirements for growth. Another is that changing requirements may cause a configuration change where a misalignment could cause vibration that could set up stresses and lead to fatigue failure. Another example is the lubrication system if included as part of the gearbox design, assuring that the lubrication capacity and filtration system is adequate considering the operating environment of the total system. The lubricant flow should be designed so that the particles within the filtration system are removed prior to reentry into the gearbox area. Gears and Splines 8-1 Revision A

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