In this study, a non-Newtonian, transient, isothermal, mixed EHL model is proposed for helical gear contacts. The model accounts for non-elliptical contacts subject to spatially varying sliding and rolling velocity fields that are not aligned with any principal axis of the contact region, which is the case for helical gear contacts. The time-varying changes pertaining to key contact parameters and relative motion of roughness profiles on mating tooth surfaces are captured simultaneously to follow the contact from the root to the tip of a tooth while accounting for the transient effect due to relative motions of the roughness profiles. Actual tooth load distributions, contact kinematics, and compliances of helical gear contacts are provided to this model by an existing helical gear load distribution model. Measured 3D roughness profiles covering the entire meshing zone are incorporated in the analyses to investigate its impact on the EHL conditions as well as mechanical power loss. Results of a parametric sensitivity study are presented to demonstrate the influence of operating conditions and surface roughness on the EHL behavior and the resultant gear mesh mechanical power loss of an example helical gear pair. The accuracy of the proposed mixed EHL model is assessed by comparing the mechanical power loss predictions to available experimental results.

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