ARTICLE IN PRESS

International Journal of Mechanical Sciences 48 (2006) 1471–1480

www.elsevier.com/locate/ijmecsci

Contact problems of a trochoidal-gear pump$

P.J. Gamez-Monteroa,, R. Castillaa, M. Khamashtab, E. Codinaa
a
Department of Fluid Mechanics, Technical University of Catalonia, Colom 7, 08222 Terrassa, Spain
b
Department of Mechanical Engineering, Colom 7, 08222 Terrassa, Spain
Received 27 September 2005; received in revised form 27 June 2006; accepted 28 June 2006
Available online 22 August 2006

Abstract

The aim of the approach of this paper is to characterise contact stress of a trochoidal-gear set when it works as part of the hydraulic
machine. It is important to know that the contact stress forces in a trochoidal-type machine is important because the machine cannot be
adjusted for wear. The main difficulty in calculating the contact forces is to determine the forces that are transmitted through each
contact point. Since there are many points of contact, at any instant, the problem is statically indeterminate. The first part of this paper
presents a simplified analytical model of a trochoidal-type machine when friction at the contact points is neglected. From this study, the
performance of the gear set is evaluated through the calculation of the normal maximum contact stress in the gear teeth. Then the second
part of the paper presents a finite element model of the same machine. The analysis of both models is for quasi-static conditions. An
experimental approach using a prototype model of the gear set provides the maximum contact stress on a pair of teeth through
photoelasticity measurement techniques of the same machine. The results from the two models and the experimental work are compared
and important conclusions are drawn and discussed.
r 2006 Elsevier Ltd. All rights reserved.

Keywords: Trochoidal-gear pump; Contact stress; Finite element method; Photoelasticity techniques

1. Introduction analysed. Taking into account the performance of the gear

Internal gear pumps can be found in a wide range of
applications due to a number of their advantages. The
automobile industry has focused on them, especially in the
trochoidal-type machines. Some of the advantages are less
noise, few components and no sealing units. Nevertheless,
it is essential to characterize the performance of the gear set
because several advantages of their design can become
disadvantages in their performance and need to be
$
Within the knowledge of the authors, no evidence was found in the
open technical literature of research work addressing in-depth studies of
wear of trochoidal gears based on contact stress and friction, except for
Colbourne’s work. There is no evidence found of a whole study of a
trochoidal gear taking into account analytical modulation, FEM
simulation and experimental work. It is for this reason that a few
references to the previously published material are provided in this paper
and a general bibliography of the main important centres working on
trochoidal gears is also included.
Corresponding author. Tel.: +34 93 73 98 085; fax: +34 93 73 98 086.
E-mail address: pjgm@mf.upc.edu (P.J. Gamez-Montero).
teeth, a disadvantage in the design of trochoidal-type
pumps is a lack of parts that can be adjusted to compensate
for wear in the gear set, and as a consequence, it causes
sharp reduction of efficiency. Therefore, when the gears
become worn they must simply be replaced.
The contact stress between the gear teeth in a trochoidal-
type machine whose internal gear is based on a trochoidal
profile, and henceforth referred to as gerotor pump, is
addressed in this paper. There is no guiding gear set in a
gerotor pump and the motion of both the gears is caused
by the contact forces between them at the contact points.
Several researchers have investigated the direct contact
problem. Colbourne [1] simplified the problem by neglect-
ing friction at the contact points and, in this way, obtained
analytical solutions, which can be used to modify the gear
parameters and reduce contact stress. However, it is only
valid for envelopes formed by circular-arc teeth. Based on
Colbourne’s theory, an analytical model has been devel-
oped, implementing a new variant to the calculation of the
contact points, and results of the maximum contact stress

0020-7403/$ - see front matter r 2006 Elsevier Ltd. All rights reserved.
doi:10.1016/j.ijmecsci.2006.06.013
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1472 P.J. Gamez-Montero et al. / International Journal of Mechanical Sciences 48 (2006) 1471–1480
Nomenclature
Latin symbols
a contact band distance
cv volumetric capacity
d normal distance to contact force
e eccentricity
F contact force per unit length
G radius of circle to complete external gear
H gear thickness
I instantaneous centre of relative motion
m distance IPs (Fig. 1)
O gear centre
r pitch circles
P fluid pressure
Ps singular point centre of the arc radius S
Pk contact point k ¼ 1, 2, y, Z
Qk centre of curvature
Qs specific flow
R2 distance O2Ps (Fig. 1)
S arc radius of the external gear tooth
Vk volume of a generic chamber
xpc, ypc coordinates of the contact point
x, y coordinates of the gear profile
in the gear teeth are obtained. The main difficulty in
calculating the contact stress is to determine the force that
is transmitted through each contact point. Since there are
many contact points, at any instant, the problem is
statically indeterminate. Despite the fact that the correct
selection of the design parameters allows reaching an
optimal contact stress, it cannot be forgotten that these
geometrical parameters also perform the volumetric
characteristics of the pump. Therefore, specific flow,
volumetric capacity, delivery irregularity and tooth stress
characteristics are presented based on the basic geometrical
parameters, on one hand, to know the influence of the
design parameters of the gear in order to reduce the
maximum contact stress and obtain the optimal volumetric
characteristics and, on the other hand, to guide the
designer to select the best design parameters in a specific
application.
The study presented in this paper also carries out a
simulation and experimental work for a specific unit of
gerotor pump for IC engines lubrication. Simulation has
become an essential tool to attain a future optimal
behaviour in systems and hydraulics components, espe-
cially when they are being designed. A series of simulations
has been performed using a finite element technique to
predict the maximum contact stress in the gear teeth for a
specific position.
The complementary experimental work tests the specific
unit of gerotor pump through photoelasticity techniques.
This technique is not very accurate and it works to obtain
X, Y absolute reference
Z, (Z
1) number of external, internal teeth
Greek symbols
apc angle of the contact point
ag angle of generation
dQ irregularity flow index
f pressure angle
g tangent to the contact point
l contraction index
r vector ray
u equidistant index
o angle of rotation
c rotation of external gear relative to internal
gear
Subscripts
1i inner/internal gear
2e outer/external gear
A, B contact points dividing low and high-pressure
(Fig. 1)
k generic contact point
pc contact point
the magnitude range of the contact stress. However, it is
essential that comparisons be made with experimental
results wherever possible. A prototype model of the gear
set of the specific unit and a test rig is designed and
constructed to measure the maximum contact stress in the
gear teeth.
The remainder of the paper is subdivided as follows:
Section 1 presents the introduction of the work carried out
in this paper. Section 2 presents the gear geometry and the
line of contact. From the line of contact, the basis of the
analytical model developed based on Colbourne’s theory is
presented. Results of the maximum contact stress and a
comparison of the volumetric characteristics and the
maximum contact stress are shown. Section 3 presents
the finite element model of the gerotor pump. Results of
the maximum contact stress are compared and contrasted
with those obtained by the analytical model. Section 4
presents the experimental work by using the photoelasticity
techniques with a prototype of the gear set. Results are
compared with those obtained through the analytical
model. Finally, conclusions for the contact problem are
then discussed.
2. Analytical model of contact stress in the gear teeth
Essentially, an internal gear pump type gerotor consists
of a pair of gear: an inner rotor with external teeth called
inner/internal gear and an outer ring with internal teeth
called outer/external gear (Fig. 1). The two gears are mated
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Y Therefore, it puts forward to introduce another methodol-

ogy to estimate the line of contact and gear geometry in the
internal gear Ps present analytical model.
It was Nervegna et al. [2,3] who defined the line of
S
contact,
m

 S

B G R2 P2 xpc apc ¼ R2 cos apc
R2 cos apc  r2 ,
m
r2

αpc S

ypc apc ¼ R2 sin apc
R2 sin apc ,
A P1 m
O2 O1 I X
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
ffi
e pitch circles m¼ r22 þ R22  2r2 R2 cos apc , ð1Þ
r1 where the sign is taken negative for the reference position of
Fig. 1. Internal gear contains all the contact points during a
line of contact complete rotation of the gear set, so the line of contact
referred to O2 describes its profile xi(agi), yi(agi) ¼ f(R2, S, e, Z
1), which is
external gear in turn the function of four geometrical parameters. To
determine the external gear, its profile must be determined
geometrically by parts xe(age), ye(age) ¼ f(R2, S, G, Z), which
Fig. 1. Gear set and line of contact in reference position.
is in turn the function of four geometrical parameters. Both
profiles are shown in the reference, set forth in Fig. 1. For any
so that each tooth of the internal gear is always in sliding other position of the gear set, profiles can be generated by the
contact with the external gear, which are known as contact applying rotation equation,



points. The external gear has Z teeth, one tooth more than xr;j ðoj Þ ¼ xj agj cos oj
yj agj sin oj ,
the internal gear and then, there are Z contact points. The


yr;j ðoj Þ ¼ xj agj cos oj þ yj agj sin oj , ð2Þ
idea underlying this method based on Colbourne’s theory
is to equalize the hydraulic and stress moments, and thus, where j ¼ i for the internal gear and j ¼ e for the external
the first goal is to calculate the positions of each contact gear [4].
point. Once the position of each contact point is
determined for any particular position of the gears, two 2.2. Calculation of contact stress and stress moment
of them serve as seals between the high- and low-pressure
sections of the fluid. Knowing their coordinates enables Fig. 2 shows a kinematic inversion in which the entire
calculation of the force on each gear caused by the fluid system has been given a counter clockwise rotation of
pressure difference and hence it becomes possible to find (Z
1)c, where c is the counter clockwise rotation of the
the hydraulic moment of the couples that require to turn external gear relative to the internal gear.
each gear. The pump drive shaft is normally connected to Once the coordinates of the contact points are known at
the internal gear, so that the teeth contact forces between any position of the gear set, the idea behind this method is
the internal and external gear are transmitted through the to bring all the contact points to the first quadrant of the
contact points. However, the main difficulty in calculating external gear reference through a kinematic inversion.
the contact stress is to decide what force is transmitted Thus, contact points are studied at the position illustrated
through each tooth at the contact point. Since there are so
many contact points, the problem is statically indetermi-
ye
nate and it is required to consider the tooth deformation at ωe= 24°
Y
the contact points. The teeth contact forces must be such so
as to transmit to the external gear a mechanical moment Vk
about its centre equal to the hydraulic moment caused by
the fluid pressure. Once it has found what force is
X
transferred by each tooth, Hertz’s equations can be used
yi I φ
to calculate the contact stress. dk
Pk,e
2.1. Line of contact and gear geometry O1 ωi ωe Pk,i Ps
xi
O2 xe
The positions of each contact point for any shape of the e γ S
external gear were found by Colbourne [1]. However, the
location of the contact points and the gear geometry is
based on a mathematical analysis which derivates to a
quadratic equation and it becomes a complex resolution. Fig. 2. Kinematic inversion.
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in Fig. 2. The external gear is then brought back to its Thus, when a couple is applied to the internal gear, it will
original position by the angle oe ¼
(Z
1)c. The internal rotate a small amount about its axis, until the tooth
gear will now have its centre O1 rotated a counter clockwise deformations are large enough to provide forces whose
rotation of (Z
1)c and a clockwise rotation of c over combined moments about O2 are equal to the stress
itself. Hence, if a point Pk,i of the internal gear touches the moment on the external gear. A small rotation of Doi is
external gear at Pk,e, then the normal to the external gear at given to the internal gear and the penetration Dv caused in
Pk,e must pass through the instantaneous centre of relative each tooth is calculated. Hence, Hertz’s equations are used
motion I. By using this property, the relation between the to find the contact stress forces, and with an iterative
radii of curvature of conjugate shapes was derived by procedure the maximum contact stress is given by
L’Hôpital and quoted by Hartenberg and Denavit [5] as   2F
  syy  ¼ . (4)
1 1 1 1 1 max pa

¼
, (3)
IQk;e IQk;i r2 r1 sin fk
where Qk,e and Qk,i are the centres of curvature of the 2.3. Calculation of hydraulic moment
external and internal gears at the contact point. Knowing
the curvature of the external gear tooth because its shape is The chamber volume reaches either maximum or mini-
an arc of a circle of radius S, this relation allows one in mum values when it is symmetrical over the X-axis. Two
calculating the curvature of the internal gear tooth. contact points, A and B of Fig. 1, form the seals that separate
Finally, the stress moment of the external gear at O2 is the high-pressure fluid of the outlet port and low-pressure
the sum of the product of the contact force Fk,e located fluid of the inlet port. Thus, once all coordinates of the
along the line IPk,e and its normal distance dk to the centre contact points are known, the Energetic method can be used
O2 at the contact points. However, not all the contact (Table 2) to calculate the fluid moment on the external gear
points contribute to transmit the moment. On one hand, about O2. The force caused by the fluid pressure will have
and taking a counter clockwise rotation as a reference, the components
P DY and
P DX, and it acts through the
contact points from 2 to (Z+1)/2 will transmit the stress midpoint of the line joining the two contact points.
moment from the internal to the external gear owing to the
fact that they are active points (they are represented by 2.4. Maximum contact stress
black arrows of different lengths in Fig. 3).
On the other hand, the contact points from (Z+3)/2 to 1 A specific unit of gerotor pump has been studied in this
are not active points (they are represented by white arrows work. The trochoidal-gear set is named PZ9e285 and its
of equal lengths in Fig. 3). Black arrows shown in Fig. 3 geometrical parameters are presented in Table 1. The fluid
represent the magnitude range of the contact force for the pressure is set at P ¼ 0.5 MPa.
reference position, while white arrows represent no force. The maximum contact stress for the gear set is calculated
Since there are several contact points, the problem of by using the analytical model and results are shown in
calculating the contact forces is statically indeterminate. Fig. 4. The study observed maximum contact stress for
each contact point Pk at a specific position of the gear set,
which means the rotation angle oi for the internal gear.
Ps Z-3 ωe= 0° The positions under study are located on the interval
Ps Z-1 2
2 P Z-3 oi ¼ 04(2p)/Z due to the fact that the reference position
P Z-1 2
2 oi ¼ 01 is repeated every (2p)/Z, since it only considered
Ps2 the gear set without the influence of the inlet and outlet
Fc, Z-3 port’s position on the housing and cover.
Fc, Z-1 2
Ps Z+1 P2
2 2
B
Fc,2 2.5. Volumetric characteristics
P Z+1 d Z-1 d Z-3 S
2 Fc, Z+1 2
O2 d Z+1
2 2 d1
2 Fc,1 A The process of pumping is carried out when the
d Z+3 I P1 Ps1 movement of rotation is transmitted from the internal to
Fc, Z+3
2
2
d Z+7 d2 the external gear, creating a circulation of the increasing
d Z+5 2
2
Fc,Z
Ps Z+3 P Z+3
2 2 PZ Table 1
Fc, Z+5 Geometrical parameters gear set PZ9e285
2 Fc,Z+7
2
line of contact PsZ
centered at O2 G 35.8 mm
P Z+5 R2 40.725 mm
P Z+7 S 10.85 mm
Ps Z+5 2
2
2 e 2.85 mm
Ps Z+7
2 H 9.25 mm
Z 9
Fig. 3. Contact forces.
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volume of the sealed pockets of fluid from the inlet to the Volumetric characteristics mainly contain chamber vo-
outlet port of the pump. Both gears rotate in the same lume, volume variation, instantaneous flow, volumetric
direction, however, at different speeds because of the capacity and delivery irregularity. There are two main
relation between the teeth, being slightly faster for the approaches to calculate the volumetric characteristics: the
internal than the external. The angular velocity ratio is integral-derivative approach and the derivative-integral
(Z
1)/Z. approach [4]. However, there are several methods and
developments to determine the volume and volume variation,
55 which are summarized in Table 2 and whose equations are:
50 Pk=1



V k apck ¼ V 1 apc1 þ ðk
1ÞDapc , (5)
45 Pk=2
Max. Contact Stress [MPa]

Pk=3  
40 dV c 1

 Z
Pk=4 ¼ H r2eA
r2eB þ r2iB
r2iA , (6)
35 Pk=5 dapc 2 Z
1
30 Pk=6 Z apc
25 Pk=7

 dV c
Pk=8
V 1 apc ¼ V 1 apc ¼ 0 þ dapc , (7)
20 0 dapc
Pk=9
15    
dV u 1 2 r1 2 r1 2
10 ¼ H Rei
Rie
r1 ðr1
r2 Þ
1
u , (8)
doi 2 r2 r2
5
0 Z þp=Z
dV u
0 5 10 15 20 22.5 25 30 35 40 cv ¼ ðZ
1Þ doi , (9)
Position
i [º]
p=Z doi

Fig. 4. Analytical study of maximum contact stress vs. position (oi) at the V umax
V umin
contact point Pk.
dQ ¼ . (10)
V umed

Table 2
Summary of volumetric approaches

Approach

Integral-derivative Derivative-integral approach

 Necessary determination of gear profiles  Unnecessary determination of gear profiles

 Volume by numerical integration and volume variation by  Volume variation by numerical differentiation and volume by
numerical differentiation numerical integration

Method

Integral method Vector rays method Energetic method

 Based on knowing all contact points at any  Based on nearest contact points  Based on the contact points which close the
position of the chamber which close the chamber maximum and minimum volume at Dapc
 Volume calculation by following a scheme of  Volume variation calculation by  Volume variation calculation by following the
resolution following the external gear rotation internal gear rotation
 It is not possible to know explicitly the  It is not possible to simplify the  It is possible to simplify the calculation of the
magnitude of the vector of the contact point calculation of the contact points contact points

Development

Variation Variation Projection Projection

 Idea: volume variation for a  Idea: gear rotation different  Idea: augment of volume gives  Idea: reduction of the volume
generic chamber from contact point rotation sign to the flow projection gives sign to the moment
develop projection development

Volume variation equations

Numerical differentiation Eq. (5) Eq. (5) Eq. (6) Eq. (8)

Chamber volume equations

Eq. (5) Eq. (7) Eq. (7) Analytic integration Eq. (8)
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It was shown by Stryczek [6] that volumetric characteristics of 3. Two-dimensional quasi-static FEM analysis
the gear set can also be based on four basic design parameters
like instantaneous flow (Eq. (8)), volumetric capacity (Eq. (9)) Simulation work is now taken under study for a specific
and delivery irregularity (Eq. (10)) are a function of unit. Broadly speaking, the pump evaluated in this study
f(M, Z, l, v), where Vumax, Vumin and Vumed are the maximum, consists of four main components: an external and an
minimum and average value of the delivered volume per internal gear named PZ9e285 gear set, a housing and a
tooth of the internal gear. For further information, consult cover. The pump without the cover is shown in Fig. 6. A
the reference of Gamez-Montero [4]. relief valve is located in the housing, which has a pressure
cracking of 0.6 MPa.
2.6. Maximum contact stress vs. volumetric characteristics
3.1. Modelling procedure
Geometrical parameters and operating conditions per-
form the volumetric characteristics and the maximum The geometric modelling has focused on the theoretical
contact stress. Most influential parameters were found to profiles of the two main components of the pump: internal
be the operating pressure and the number of teeth. Owing and external gear. It does not take into account the
to the fact that for lubricating pumps, operating pressure is manufacturing, clearance and thermal effects in this
relatively low and can therefore be excluded from the focus preliminary approach. Basically, two types of software
of this analysis. With regard to the contact stress, the have been used for the three main stages of the simulation.
influential parameter is also the minimum radius of At the first stage, GiD v7.0 software has been used as the
curvature of the internal gear. For a chosen PZ9e285 gear pre-processor to create the geometry of the gear set and
set with geometrical parameter of Table 1, Fig. 5 depicts later to develop the mesh. At the second stage, COMET
the maximum contact stress and the volumetric character- v5.0 software has been used to calculate the contact stress
istics vs. number of teeth, where Qs is the pump-specific at the contact points. COMET v5.0 software is a
flow, a dimensionless form of the volumetric capacity cv mechanical solver using the finite element method
useful to compare performance of various types of gearing. (FEM). At the third stage, GiD v7.0 software has been
It can be observed that the evolution of the volumetric used again as post-processor in order to display the results.
characteristics and the maximum contact stress (syy) are Both the software have been developed at the International
opposite. While the volumetric characteristics become Centre for Numerical Methods in Engineering of Barcelo-
better as the number of teeth increases, the contact stress na (CIMNE). The software used in this work is accurate
becomes worse. And vice versa. Note that there is a enough to make stress predictions. However, new finite
significant inflexion point between the 10th and 11th teeth element techniques can be found in the bibliography [7].
where the maximum contact stress suffers an important The profiles of the gears have to be defined very
increase. The authors believe that the influence of the accurately in order to obtain a correct geometry of the
minimum radius of curvature of the internal gear is critical. assembled gear set. Initial penetration has to be avoided
By increasing the number of teeth, its shape becomes because a virtual interference would appear producing
sharper and it produces high contact forces. Moreover, unreal results. That phenomenon is illustrated in Fig. 7.
facing with the trend of high-speed applications, increasing Fig. 8 shows the FEM mesh of the assembled gear
attention has been focused on it. The optimum value seems set. The mesh is constructed by 26,270 unstructured
to be at the 9th teeth to the external gear for the chosen
geometrical parameters.

15 600
14 560
Max. Contact Stress [MPa]

13 520
Volumetric Characteristics

12 480
11 QS [-] 440
10 400
9 δQ [%] 360
8 cv [cm3/rev] 320
7 σyy [MPa] 280
6 240
5 200
4 160
3 120
2 80
1 40
0 0
8 9 10 11 12
Number of Teeth (Z)

Fig. 5. Comparison of gear set vs. number of teeth. Fig. 6. Specific unit of gerotor pump.
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Fig. 7. Geometry of the assembled gear set PZ9e285.

Fig. 8. Mesh assembled gear set and its density.

triangles with 17,845 nodes. The elements have been more

concentrated on the gear profiles. That is because the
entire internal gear profile becomes a contact point at
any time of one complete revolution and the curvature
of its teeth. Hence, the mesh density increases the
required CPU time extremely and this has to be taken
into account.

3.2. FEM mechanical analysis simulation

The mechanical analysis has been implemented in the

simulation model. The gear set is stabilized at a specific
position of study. Then, a small rotation of Doi is given to
the internal gear and the contact stress at the contact point Fig. 9. FEM analysis.
is calculated by the penalty of the penetration caused in
each tooth. The analysis has been carried out in a quasi-
static mode in ten steps without taking into account
the dynamic components from the deformation equations. Results of the maximum contact stress of the analytical
Fig. 9 shows an example of the analysis and Fig. 10 shows and FEM model are plotted in Fig. 11 in order to compare
results of the maximum contact stress at each contact point the exactitude of each method. It seems that the FEM
through the finite element model. model shows greatest values of the maximum contact stress
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55
50 Pk=1
45 Pk=2
Max. Contact Stress [MPa]

40 Pk=3
Pk=4
35
Pk=5
30 Pk=6
25 Pk=7
Pk=8
20
Pk=9
15
10
5
0 Fig. 12. Contact stress under polarized light.
0 5 10 15 20 22.5 25 30 35 40
Position
i [º]

Fig. 10. FEM study of maximum contact stress vs. position (oi) at the
contact point Pk. 40
35
Max. Contact Stress [MPa] 30
55 Pk=1
Pk=2
50 25
Pk=3
45
Max. Contact Stress [MPa]

Analytical Model 20 Pk=4

40 Finite Element Method Pk=5
15 Pk=6
35 Pk=7
30 10
Pk=8
25 5 Pk=9

20 0
15 0 4.5 9 13.5 18 22.5 27 31.5 36 40.5
10 (a) Position
i [º]
5
40
0
0 5 10 15 20 22.5 25 30 35 40 35
Max. Contact Stress [MPa]

Position
i [º]
30 Pk=1
Fig. 11. Comparison of analytical and FEM study. 25 Pk=2
Pk=3
20 Pk=4
Pk=5
15 Pk=6
at each position of study. Nevertheless, the precision of Pk=7
both studies is quite accurate. 10
Pk=8
5 Pk=9
4. Experimental work 0
0 4.5 9 13.5 18 22.5 27 31.5 36 40.5
A testing phase is also taken into account for the specific (b) Position
i [º]
unit pump PZ9e285. Photoelasticity techniques are used to
Fig. 13. Analytical study (a) and photoelasticity techniques (b) of the
evaluate the magnitude of the contact stress at the contact maximum contact stress vs. position (oi) at the contact point Pk.
point. Through a polarized light, contact stress appears as
a spectrum of colours. Each colour corresponds to a
specific contact force and it can be calibrated in a test
bench. Once the spectrum of colour has been calibrated to has been chosen, which is the most commonly used
match the pair of values of the colour-contact force, then material because of its transparency and mechanical
contact stress magnitude ranges can be determined in a test qualities. It has a Young’s modulus of 3000 MPa. The
rig. Furthermore, a test rig has been designed and accuracy of the gear profiles is very important and is taken
constructed to perform the tests (Fig. 12). into account in the construction of the prototype.
A prototype model of the gear set has been designed and The test rig is developed to transmit a specific moment
constructed in a scale of 3:1 and it has to be transparent in from the internal to the external gear. At the same time,
order to use the photoelasticity techniques. Epoxy material polarized light can pass through the pair of teeth under
 ARTICLE IN PRESS
P.J. Gamez-Montero et al. / International Journal of Mechanical Sciences 48 (2006) 1471–1480
study and measures the contact stress of its calibrated
colour spectrum. The contact force is then produced in the
pair of teeth under study.
However, that technique just allows obtaining visual
measurements through the spectrum of colours. Unfortu-
nately, they cannot be very precise. The quality of the
results is mainly based on two factors: the precision of the
reading of the pair of values of the colour-contact force
and the accuracy of the gear profiles. Both of them have
been taken into account in the construction of the
prototype and the test rig.
The analytical study and the testing phase work have
been done with the same geometrical and material
parameters, as that of the prototype model named
MZ9e855. Several torques from the internal to the external
gear have been studied, and results with a torque of
37.5 Nm are presented in Fig. 13 for the testing phase and
the analytical study.
5. Conclusions
Two analytical methods have been presented to calculate
the contact stress and the volumetric characteristics to a
gear set when it works as a part of an internal gear pump
type gerotor. Results of the maximum contact stress and
the volumetric characteristics are presented to compare and
contrast several geometries of a gerotor gear sets. Results
of the contact stress of the analytical method, modelling
and simulation, and experimental work are also presented
for a specific unit of a gerotor pump.
Results of the contact stress have shown a good
agreement of the magnitude range and active contact point
location between the analytical study and the FEM
simulation at the contact points. However, disagreement
appears at the value of the maximum contact stress at each
contact point. It seems clear that modelling needs to be
very accurate to the geometry of the gear profiles. Besides,
the mesh density has to increase regardless of the penalty of
the required CPU time.
The final aim is to optimize the teeth profile in order to
minimize the wear in the gears. The analytical study and
FEM simulation are models that deal with quasi-static
conditions. The analytical study is a model of the Hertz’s
equations that calculates the contact stress and FEM
simulation is a quasi-static mode in ten steps without
taking into account the dynamic components in the
deformation equations. The authors are aware of the
limitations of both methods because they should have
focused on the influence, not only of the contact stress, but
also the wear produced because of the relative velocity
between the inner and outer gears. Nevertheless, the
authors also believe that the knowledge of the contact
stress obtained by both the methods gives an optimum
exactness to take into consideration the results and to
continue this work.
The variation of the number of teeth is studied in a gear
set in order to compare its influence on two performance
1479
magnitudes: maximum contact stress and volumetric
characteristics. The result shows that both magnitudes
have opposite behaviour against the number of teeth, and
the improvement of one of them makes the other worse. An
agreement between both magnitudes has to be considered if
it wants to reach the optimum design.
Despite the limitations of the photoelasticity technique, a
correct agreement of the magnitude range of the contact
stress between the analytical study and the photoelasticity
tests has been shown. Nevertheless, results disagree with
each other at the location of the maximum contact stress at
each contact point. The reason is that it missed one contact
point in the testing phase because of the impossibility of
detecting a change colour and the contact stress at the last
active contact point.
Indeed, the magnitude range given by the spectrum of
colours is the qualitative information of the contact stress,
which then disagrees with the analytical model. The
deformation of the model made by Expoxy, masks precise
quantitative information of the contact stress because of
two main reasons: the lack of precision of the measure
at the zone very close to the contact point and the scale of
the model. All the measures and accuracy were taken care
of during the experimental work in order to ensure the
most accurate experimental results of the contact stress.
Despite that, the authors are aware that the zone nearest to
the contact point is unable to see all the spectrum of
colours.
Inaccuracies on the results appear and it is clear that
caution must be exercised when interpreting analytical,
FEM simulation and experimental results. Nevertheless,
there are physical facts that we are unable to simulate just
because we are still far from comprehending all their
involver contents, particularly for complex structures of the
gerotor pump.
Acknowledgments
The authors would like to acknowledge the support of
the companies AMES (Spain) and Pedro Roquet (Spain)
for providing the necessary support. Thanks are also due to
the CIMNE (Spain) for provision of software and for his
liaison work with FEM.
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