Currently legislation is in place to encourage a reduction in energy usage. As such there is an increased demand for machinery with higher efficiencies, not only to reduce the operational costs of the machinery, but also to cut capital expenditure. The power losses associated with the gear mesh can be divided into speed and load dependant losses. This paper reviews some of the mathematical models proposed for the individual components associated with these losses, such as windage, churning, sliding and rolling friction loses. A mathematical model is proposed which predicts the power losses on helical gears highlighting the major contributor to losses in the gear mesh. Furthermore, the mathematical model is validated with a case study.

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