Search Results (507)

The involute gear with variable tooth thickness lacks established methods for calculating meshing heat and studying oil-jet lubrication and cooling effects. This study aims to theoretically estimate the meshing heat generated during the engagement process of involute gears with variable tooth thickness. To achieve this, a heat calculation model is derived based on the corresponding tooth surface equations. The impact of oil-jet lubrication parameters—jet velocity, pitch cone angle, face width ratio, and axial displacement—on the gear surface temperature and internal gearbox environment is systematically studied. Numerical simulations of the temperature field are validated through experimental measurements. The results indicate that an oil-jet velocity of 15 m/s combined with a pitch cone angle of 4° significantly reduces both gear surface and internal flow field temperatures. Additionally, smaller face width ratios and axial displacements effectively lower the internal temperature of the gearbox. These findings offer a theoretical basis for calculating meshing heat and designing oil-jet lubrication systems for variable-tooth-thickness involute gears. Full article

Electric propulsion requires engines and transmission systems that run at higher speeds compared to combustion engines. For improving sustainability and environmental protection, biodegradable oils are suggested for the lubrication of high-speed gears that require particularly quick wetting of the steel surfaces. Newly developed promising candidates include short-chained polyalphaolefins. In the present work, a study on the applicability of such oil is presented and discussed with respect to different aging levels based on biodegradable properties. It focuses on the wettability of metallic surfaces investigated through time-resolved contact angle measurements. Carbon steels with different carbon contents and microstructures are selected as the most commonly used materials for gears. Effects of steel composition, surface roughness and oil oxidation are studied. The results show that in most cases, the application of biodegradable polyalphaolefins is not critical; however, a combination of steels with inhomogeneous microstructure, high surface roughness and aged oil can be critical because of limited wetting. Full article

Line laser measurement, as a typical method of laser triangulation, makes the acquisition of 3D tooth-surface data more accurate, efficient, and informative. Thus, a line laser 3D measurement model of gears is established, and a specialized polyhedral artifact with specific geometric features is invented to determine the pose parameters of the line laser sensor in measuring space. Based on this, a single-spindle gear-measuring instrument is developed and a series of experimental studies are conducted for gears with different module and flank directions in this instrument, including profile deviation, helix deviation, pitch deviation, topological deviation, etc. A comparative experiment with traditional contact measurement methods validates the correctness of the methods mentioned in this paper for the accurate evaluation of tested gears. In further research, the mining and utilization of big data obtained from the line laser 3D measurement of gears will be an important topic. Full article

Repairing veneer defects is the key to ensuring the quality of plywood. In order to improve the maintenance quality and material utilization efficiency during the maintenance process, this paper proposes a bidirectional maintenance method based on gear rack transmission and its related equipment. Based on the working principle, a geometric relationship model was established, which combines the structural parameters of the mold, punch, and gear system. Simultaneously, it solves the problem of motion attitude analysis of conjugate tooth profiles under non-standard meshing conditions, aiming to establish a constraint relationship between stamping motion and structural design parameters. On this basis, a constrained optimization model was developed by integrating multi-objective optimization theory to maximize maintenance efficiency. The NSGA-III algorithm is used to solve the model and obtain the Pareto front solution set. Subsequently, three optimal parameter configurations were selected for simulation analysis and experimental platform construction. The simulation and experimental results indicate that the veneer repair time ranges from 0.6 to 1.8 seconds, depending on the stamping speed. A reduction of 28 mm in die height decreases the repair time by approximately 0.1 seconds, resulting in an efficiency improvement of about 14%. The experimental results confirm the effectiveness of the proposed method in repairing veneer defects. Vibration measurements further verify the system’s stable operation under parametric modeling and optimization design. The main vibration response occurs during the meshing and disengagement phases between the gear and rack. Full article

Reducing gear noise in electric vehicle (EV) drivetrains is crucial due to the absence of internal combustion engine noise, making even minor acoustic disturbances noticeable. Manufacturing parameters significantly influence gear-generated noise, yet traditional analytical methods often fail to predict these complex relationships accurately. This research addresses this gap by introducing a data-driven approach using machine learning (ML) to predict gear noise levels from manufacturing and sensor-derived data. The presented methodology encompasses systematic data collection from various production stages—including soft and hard machining, heat treatment, honing, rolling tests, and end-of-line (EOL) acoustic measurements. Predictive models employing Random Forest, Gradient Boosting (XGBoost), and Neural Network algorithms were developed and compared to traditional statistical approaches. The analysis identified critical manufacturing parameters, such as surface waviness, profile errors, and tooth geometry deviations, significantly influencing noise generation. Advanced ML models, specifically Random Forest, XGBoost, and deep neural networks, demonstrated superior prediction accuracy, providing early-stage identification of gear units likely to exceed acceptable noise thresholds. Integrating these data-driven models into manufacturing processes enables early detection of potential noise issues, reduces quality assurance costs, and supports sustainable manufacturing by minimizing prototype production and resource consumption. This research enhances the understanding of gear noise formation and offers practical solutions for real-time quality assurance. Full article

Worm gears are used in various mechanical constructions, especially in heavy industrial plants, where they are exposed to high operating loads, large torques, and high temperatures, particularly in conditions where it is necessary for the input and output shafts to be at an angle of 90°. Regarding tribological optimization, the application of carbon nanotube in lubricants can lead to significant improvements in the performance characteristics of worm gears, both in terms of increasing efficiency and reducing the coefficient of friction and wear, as well as minimizing mechanical losses, noise, and vibrations. The objective of this study is for the research results, through the use of oil with varying percentages of carbon nanotube additives (CNTs), to contribute to the optimization of worm gears by improving efficiency, extending service life, and reducing vibrations—both within the gearbox itself and within the industrial facility where it is applied. The research methodology involved laboratory testing of a worm gear using lubricants with varying concentrations of carbon nanotube. During the experiment, measurements of efficiency, vibrations, and noise levels were conducted in order to determine the impact of these additives on the operational performance of the gear system. The main contribution of this research is reflected in the experimental confirmation that the use of lubricants with optimized concentrations of carbon nanotube significantly enhances the operational performance of worm gears by increasing efficiency and reducing vibrations and noise, thereby enabling tribological optimization that contributes to improved reliability, extended service life, and enhanced workplace ergonomics under demanding industrial conditions. Furthermore, experimental investigations have shown that the efficiency of the gearbox increases from an initial value of 0.42–0.65, which represents an increase of 54%, the vibrations of the worm gear decrease from an initial value of 5.83–2.56 mm/s², which represents an decrease of 56%, while the noise was reduced from 87.5 to 77.2 dB, which represents an decrease of 12% with the increasing percentage of carbon nanotube additives in the lubricant, up to a maximum value of 1%. However, beyond this experimentally determined threshold, a decrease in the efficiency of the tested worm gearbox, as well as an increase in noise and vibration levels was recorded. Full article

This study investigates the use of a custom-built 10 GHz continuous wave micro-Doppler radar system to analyze external vibrations of idling vehicles under various conditions. Scenarios included different gear engagements with one occupant and parked gear with up to four occupants. Motivated by security concerns, such as the threat posed by idling vehicles with multiple occupants, the research explores how micro-Doppler signatures can indicate vehicle readiness to move. Experiments focused on a mid-size SUV, with similar trends seen in other vehicles. Radar data were compared to in situ accelerometer measurements, confirming that the radar system can detect subtle frequency changes, especially during gear shifts. The system’s sensitivity enables it to distinguish variations tied to gear state and passenger load. Extracted features like frequency and magnitude show strong potential for use in machine learning models, offering a non-invasive, remote sensing method for reliably identifying vehicle operational states and occupancy levels in security or monitoring contexts. Spectrogram and PSD analyses reveal consistent tonal vibrations around 30 Hz, tied to engine activity, with harmonics at 60 Hz and 90 Hz. Gear shifts produce impulse signatures primarily below 20 Hz, and transient data show distinct peaks at 50, 80, and 100 Hz. Key features at 23 Hz and 45 Hz effectively indicate engine and gear states. Radar and accelerometer data align well, supporting the potential for remote sensing and machine learning-based classification. Full article

The aim of the present study is to investigate the influence of Nickel–Hexagonal Boron Nitride (Ni-hBN) nanocomposite coatings, deposited using the pulse reverse current electrodeposition technique. This experimental study focuses on assessing the tribological and corrosion properties of the produced coatings on the SS304 substrate. The microhardness of the as-deposited (AD) sample and heat-treated (HT) sample were 49% and 83.8% higher compared to the control sample. The HT sample exhibited a grain size which was approximately 9.7% larger than the AD sample owing to the expansion–contraction mechanism of grains during heat treatment and sudden quenching. Surface roughness reduced after coating, where the Ni-hBN-coated sample measured a roughness of 0.43 µm compared to 0.48 µm for the bare surface. The average coefficient of friction for the AD sample was 42.4% lower than the bare surface owing to the self-lubricating properties of nano hBN. In particular, the corrosion rate of the AD sample was found to be 0.062 mm/year, which was lower than values reported in other studies. As such, findings from the present study can be particularly beneficial for applications in the automotive and aerospace industries, where enhanced wear resistance, reduced friction, and superior corrosion protection are critical for components such as engine parts, gears, bearings and shafts. Full article

As a core component of a fully automatic pepper transplanter, the performance of the seedling-picking mechanism is of particular significance. However, existing seedling-picking mechanisms have problems such as being prone to damaging the seedling roots and substrate, as well as having poor stability. To develop a highly efficient, stable, and minimally damaging seedling-picking mechanism, this study proposed a design scheme for a stem-clamping-and-pulling-out-type seedling-picking end actuator driven by a non-circular gear system. The specific methods and objectives include the following: (1) designing a differential non-circular gear system to replicate a manual picking trajectory accurately; (2) establishing a kinematic model and developing optimization software to determine the optimal parameter combination; (3) experimentally validating the mechanism’s performance through virtual simulations and bench tests. The bench tests showed that the mechanism could complete two seedling-picking operations per rotation, extracting an entire row (eight plants) in a single rotation at a speed of 30 r/min. The measured angles of the end effector at four key postures were highly consistent with simulation and high-speed camera data, with all key posture errors less than 1°. These results demonstrate the mechanism’s high accuracy, efficiency, and reliability. Full article

Elasmobranch species are considered a global conservation priority due to their susceptibility to fishing pressure. In the Madeira Archipelago, Northeastern Atlantic, most elasmobranch species are caught as bycatch in artisanal drifting longline fishery targeting scabbardfishes. All commercial elasmobranch landings carried out in this archipelago over three decades (1990–2020) were analysed, aiming to provide a reliable overview of Madeira’s elasmobranch fisheries and their evolution. A total of 2316 tonnes of elasmobranchs were landed during the study period, corresponding to approximately EUR 2.1 million in first-sale value. The most representative period occurred from 2003 to 2013, corresponding to 75.21% of the total elasmobranch landings. A general pattern of supply and demand was evident, with mean price values typically showing an inverse trend to landed tonnage. At the species level, Centrophorus squamosus appears as the dominant species, representing about 89% of the total elasmobranch species landed, followed by Prionace glauca, with approximately 3%. The high dominance of C. squamosus in the scabbardfish fishery raises significant ecological and management concerns, as this deep-water shark species is known for its vulnerability to overexploitation. Management measures currently in place need to be updated and ought to be based on studies on the type and size of hooks for each fishery, to ultimately infer about species-specific survival rates, as well as the fishing gears’ soak time. Moreover, studies on the enhancement of food supply through fisheries discards are still missing, even though it is highly likely that this input may alter the dynamics of marine food webs. Full article

The manufacture of lightweight components is one of the most important requirements in the automotive and aerospace industries. Gears, on the other hand, are among the heaviest parts in terms of their total weight. Accordingly, a spur gear was considered, the body of which was configured as a lattice structure to make it lightweight. In addition, the structure was optimized by topology optimization using ProTOP software. Subsequently, the gear was manufactured by a selective laser melting process by using a strong and lightweight material, namely Ti-6Al-4V. This study defeated the problems of manufacturing orientation, surface roughness, support structure, and bending due to the high thermal gradient in the selective laser melting process. To experimentally investigate the benefits of such a lightweight gear body structure, a new test rig with a closed loop was developed. This rig enabled measurements of strains in the gear ring, hub, and tooth root. The experimental results confirmed that a specifically designed and selectively laser-melted, lightweight cellular lattice structure in the gear body can significantly influence strain. This is especially significant with respect to strain levels and their time-dependent variations in the hub section of the gear body. Full article

The deployment of drones in civil airspaces has increased rapidly in recent years. However, their small radar cross-section hinders detectability by existing surveillance systems. This paper evaluates the feasibility of using additive manufacturing techniques with materials with enhanced electromagnetic properties to increase RADAR drone detectability. The examined methods include the production of propellers and landing gear with additive techniques and metal-doped plastics. Field experiments were performed measuring the radar detection range of an off-the-shelf drone with a 24 GHz RADAR module, and findings indicate that the use of specialized materials for drone manufacturing greatly improves drone detectability, increasing the detection range by a factor of 3.9 without changes to the drone design or inclusion of external electromagnetic reflectors. Full article

Gear whine noise is governed not only by intentional microgeometry modifications but also by unavoidable pitch (indexing) deviation. This study presents a workflow that couples a tooth-resolved surface scan with a calibrated pitch-deviation table, both imported into a multibody dynamics (MBD) model built in MSC Adams View. Three operating scenarios were evaluated—ideal geometry, measured microgeometry without pitch error, and measured microgeometry with pitch error—at a nominal speed of 1000 r min⁻¹. Time domain analysis shows that integrating the pitch table increases the mean transmission error (TE) by almost an order of magnitude and introduces a distinct 16.66 Hz shaft order tone. When the measured tooth topologies are added, peak-to-peak TE nearly doubles, revealing a non-linear interaction between spacing deviation and local flank shape. Frequency domain results reproduce the expected mesh-frequency side bands, validating the mapping of the pitch table into the solver. The combined method therefore provides a more faithful digital twin for predicting tonal noise and demonstrates why indexing tolerances must be considered alongside profile relief during gear design optimization. Full article

Gearboxes are critical mechanical components in various modern constructions, including wind turbines, making their real-time monitoring and the prevention of major failures essential. Machine learning (ML) offers a precise and robust method for early-stage failure detection and efficient gear monitoring during operation, with computational efficiency that allows for use on edge devices. This article presents a method for detecting surface damage on gear teeth using unsupervised machine learning. Using only experimentally measured vibrational signals from a healthy gearbox as a training set, novel neural network architectures, including convolutional and recurrent autoencoders, were employed and compared with a classical dense autoencoder. The study confirmed the effectiveness of these methods in gear transmission diagnostics and demonstrated the potential for achieving high-quality classification metrics using unsupervised learning. Full article

The contact pattern between gear teeth is one of the most significant indicators of proper gear operation. This paper presents an analysis of the contact pattern of gears with a sinusoidal profile. The gear geometry was obtained through direct solid simulation of the machining process. Generally, analytical, numerical, and experimental methods are used for contact pattern analysis in gearboxes. This article presents contact pattern investigations using numerical methods and a novel experimental method that utilizes pressure measurement films. A proprietary program using image analysis was used for the contact pattern analysis. The numerical studies utilized the Finite Element Method (FEM) and the CAD method. The results obtained from the presented methods show good convergence. Full article