An Investigation on the Teeth Crowning Effects on the Transient EHL Performance of Large-Scale Wind Turbine Spur Gears

Crowning is applied to wind turbine gears, including spur gears, to ensure adequate stress distribution and contact localization in wind turbine main gearbox gears to improve the gear performance in the presence of misalignments. Each gear tooth is crowned along the face width using a parabolic curve that graduates from a maximum height at the edges and vanishes at the center of the tooth flank. This crowning transfers the elastohydrodynamic contact problem from a line to a point contact case where the surface curvatures and pressure gradient are considered in both directions of the solution space. A wide range of longitudinal crowning heights is considered in this analysis under heavily loaded teeth for typical large-scale wind turbine gears. Furthermore, the variation in the velocities is considered in the analysis. The full transient elastohydrodynamic point contact solution considers the non-Newtonian oil behavior, where the numerical solution is based on the finite difference method. This work is focused on the evaluation of the effectiveness of teeth’s longitudinal crowning in terms of the consequences on the resulting pressure distribution and the corresponding film thickness. The modification of the tooth flank significantly elevates the film thickness levels over the zones close to the tooth edges without a significant increase in the pressure values. Moreover, the zone close to the tooth edges from both sides, where the pressure is expected to drop to the ambient pressure, is extended as a result of the flank modification.