Effect of geometry and operating conditions on spur gear system power loss

The results of an analysis of the effects of spur gear size, pitch, width, and ratio on total mesh power loss for a wide range of speeds, torques, and oil viscosities are presented. The analysis uses simple algebraic expressions to determine gear sliding, rolling, and windage losses and also incorporates an approximate ball bearing power loss expression. The analysis shows good agreement with published data. Large diameter and fine pitched gears had higher peak efficiencies but low part load efficiency. Gear efficiencies were generally greater than 98 percent except at very low torque levels. Tare (no-load) losses are generally a significant percentage of the full load loss except at low speeds.