Research Review of Gear Scuffing: Mechanism, Calculation Methods and Optimization Strategies

GUO Dong; DENG Wenfeng; LI Ming; XIN Yu; FANG Chuan

doi:10.16490/j.cnki.issn.1001-3660.2025.19.002

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Surface Technology ›› 2025, Vol. 54 ›› Issue (19) : 14-15. DOI: 10.16490/j.cnki.issn.1001-3660.2025.19.002

Research Review

Research Review of Gear Scuffing: Mechanism, Calculation Methods and Optimization Strategies

GUO Dong^a, DENG Wenfeng^a, LI Ming^a,*, XIN Yu^b, FANG Chuan^a

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Abstract

With the development of new energy vehicles, the gears in their reducers are often in extreme working conditions such as high speed, heavy load and poor lubrication, which makes the gears prone to scuffing failure during the meshing process. Gear scuffing is mainly manifested in a sharp increase in the local temperature of the tooth surface, rupture of the lubricating oil film, direct contact and adhesion of the metal surfaces, and ultimately tearing of the tooth surface material. This failure mode seriously affects the reliability and service life of the transmission system. Beyond merely reducing service life, scuffing failures in critical components like new energy vehicle reducers often lead to unpredictable breakdowns, resulting in significant economic losses due to downtime and high maintenance costs. Studying the mechanism of gear scuffing and its affecting factors is crucial to improving the durability of the gear. Improving the anti-scuffing performance of the gear is an urgent problem to be solved at present. The work aims to review the current failure mechanisms of gear scuffing, including flash temperature theory, elastohydrodynamic lubrication theory, PVT limit theory and adiabatic shear instability theory. By comparing the calculation methods in standards such as ISO 6336-20/21 and GB/Z 6413.1/2, the differences in the applicability of the integral temperature method and the flash temperature method under complex working conditions are revealed. The application of numerical calculation methods and machine learning algorithms in gear scuffing problems is analyzed. Numerical approaches, such as the finite element method, enable precise simulation of gear temperature fields under various operating conditions, offering detailed insights into thermal behavior. Concurrently, the integration of machine learning algorithms presents a powerful avenue for enhancing prediction accuracy and efficiency, particularly in handling the multifaceted variables and non-linear relationships inherent in gear scuffing problems. The key factors affecting gear scuffing are summarized, including manufacturing process, working conditions, geometric parameters and lubrication conditions. Reasonable design of macro parameters such as pressure angle and modulus can improve load distribution, while micro-modification can optimize surface contact state. Extreme pressure additives and reasonable oil supply methods can effectively enhance oil film stability. Surface strengthening treatment and coating technology can improve residual stress distribution and reduce friction coefficient. By optimizing the gear manufacturing process, improving the working and lubrication conditions of gears, and rationally designing the geometric parameters of gears, the anti-scuffing performance of gears can be effectively improved. Finally, the development trend of gear scuffing is prospected. Future research should combine multidisciplinary cross-technology, integrate advanced calculation methods and experimental means, and improve the accuracy and applicability of gear scuffing prediction. At the theoretical level, it is necessary to further explore the material failure mechanism at the microscopic scale. In terms of calculation methods, efficient numerical models coupled with multiple physical fields should be developed. Multi-faceted analyses should be conducted by integrating factors such as heat, force and flow, and machine learning techniques should be introduced to enhance the prediction efficiency under complex working conditions. In addition, efforts should focus on developing new anti-scuffing composite materials and surface engineering technologies, optimizing lubrication methods, and establishing a complete performance database for the entire life cycle of gears. These innovations will drive gear transmission systems towards greater efficiency and reliability, thereby meeting the demanding requirements of high-end application scenarios such as new energy vehicles.

Key words

gear scuffing / failure mechanism / calculation method / numerical simulation / lubrication conditions / manufacturing process

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GUO Dong, DENG Wenfeng, LI Ming, XIN Yu, FANG Chuan. Research Review of Gear Scuffing: Mechanism, Calculation Methods and Optimization Strategies[J]. Surface Technology. 2025, 54(19): 14-15 https://doi.org/10.16490/j.cnki.issn.1001-3660.2025.19.002

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Funding

Innovation and Development Joint Fund of Chongqing Natural Science Foundation (CSTB2022NSCQ-LZX0051); Science and Technology Research Project of Chongqing Education Commission (KJQN202201149)