Forecasting model for hypoid gear elastohydrodynamic lubrication considering entrainment effect.

• Dynamic loaded tooth contact analysis (DLTCA) for computing entrainment speed. • Accurate solution to elastohydrodynamic lubrication (EHL) governing equation. • Discrete convolution and fast Fourier transformation (DC-FFT) for flank elastic deformation. • A separation flow method for iteration of EHL governing equation. • Accurate entrainment effect-based EHL forecasting model for hypoid gears. In full consideration of time-varying meshing performance and oil film characteristics, entrainment effect on elastohydrodynamic lubrication (EHL) is developed for establishing accurate forecasting model of the complex hypoid gears. Firstly, dynamic loaded tooth contact analysis (DLTCA) is employed to determine the meshing interface kinematics, load distribution and entrainment speed under dynamic load condition. Then, entrainment speed is introduced into the EHL governing equation and accurate forecasting model is established. With accurate discretization of EHL governing equation, discrete convolution and fast Fourier transformation (DC-FFT) method is employed to compute the flank elastic deformation. Finally, a hypoid gear set in automotive industrial application is exercised to verify entrainment effect on EHL assessment in the proposed model. [ABSTRACT FROM AUTHOR]