The Influence of Thermal Stresses on the Load Distribution and Stress–Strain State of Cycloidal Reducers

The design of cycloidal reducers requires a detailed knowledge of the intensity and character of load, as well as the maximum von Mises stresses on critical components. In the available literature, the load distribution and the stress–strain state of the cycloidal reducer elements are typically determined based on factors such as cycloidal disc tooth profile modifications, contact deformations, and internal clearances, whereas the influence of thermal stresses is most often neglected. To address this research gap, an innovative numerical–analytical methodology has been developed, which, for the first time, enables the prediction of the distribution of temperature fields and the quantification of the influence of temperature on the contact forces and the stress–strain state of key elements of the cycloidal reducer. Furthermore, the proposed methodology can be adapted for application within a broader context of mechanical engineering. From a practical perspective, it is expected to be beneficial to companies engaged in the design of power transmission gearboxes, as valuable practical guidelines for engineering applications are provided. This study also provides new insights into the dominant sources of heat generation and offers a clearer understanding of how thermal energy is transferred from internal heat sources to the outer surface of the housing.