In this study, a surface wear prediction model for spur and helical gears is proposed. The model employs a finite elements-based gear contact mechanics model in conjunction with the Archard's wear formulation to predict wear of contacting tooth surfaces. An iterative numerical procedure is developed to account for the changes in the gear contact as the gears wear. A methodology is developed to import gear coordinate measurement machine data into the gear contact model in order to analyze gears with actual manufactured surfaces with profile and lead modifications. Results of an experimental study are presented for validation of the model. A set of simulations is also included to highlight the differences between gear pairs having modified and unmodified tooth surfaces, with and without manufacturing errors in terms of their wear characteristics.
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