Nonlinear dynamics of a spur gear pair with force-dependent mesh stiffness

Time-varying mesh stiffness is one of the main excitation sources of a gear system, and it is also considered as an important factor for the vibration and noise of gears. Thus, this excitation is usually taken as an input into the gear dynamic model to obtain the system dynamic responses. However, the mesh stiffness of a gear pair is actually nonlinear with respect to the dynamic mesh force (DMF) that fluctuates during the operation of gears. Therefore, the dynamic model of gears with the quasi-static mesh stiffness calculated under a constant load is not accurate sufficiently. In this paper, a dynamic model of spur gear is established with considering the effect of the force-dependent time-varying mesh stiffness, backlash and profile deviation. Due to the nonlinear relationship between the mesh stiffness and the load for each tooth pair, it needs first to determine the load sharing among tooth pairs and then calculate the overall mesh stiffness of the gear pair. As the mesh stiffness and DMF are related, the mesh stiffness is no longer directly taken into the gear dynamic model as an input, but is jointly solved with the numerical integration process using the gear dynamic model. Finally, the dynamic responses predicted from the established gear dynamic model are compared with the experimental results for validation and compared with the traditional models to reveal their differences. The results indicate that the established dynamic model of spur gear transmission has a wider application range than the traditional models.     

Coupled lateral-torsional-axial vibrations of a helical gear-rotor-bearing system

Considering the axial and radial loads, a math- ematical model of angular contact ball bearing is deduced with Hertz contact theory. With the coupling effects of lateral, torsional and axial vibrations taken into account, a lumped-parameter nonlinear dynamic model of helical gearrotor-bearing system （HGRBS） is established to obtain the transmission system dynamic response to the changes of dif- ferent parameters. The vibration differential equations of the drive system are derived through the Lagrange equation, which considers the kinetic and potential energies, the dis- sipative function and the internal/external excitation. Based on the Runge-Kutta numerical method, the dynamics of the HGRBS is investigated, which describes vibration properties of HGRBS more comprehensively. The results show that the vibration amplitudes have obvious fluctuation, and the frequency multiplication and random frequency components become increasingly obvious with changing rotational speed and eccentricity at gear and bearing positions. Axial vibration of the HGRBS also has some fluctuations. The bearing has self-variable stiffness frequency, which should be avoided in engineering design. In addition, the bearing clearance needs little attention due to its slightly discernible effect on vibration response. It is suggested that a careful examination should be made in modelling the nonlinear dynamic behavior of a helical gear-rotor-bearing system.     

Nonlinear dynamic characteristic of a face gear drive with effect of modification

Face gear drive is one of the main directions of research for aeronautical transmission for its advantages, but the vibration induced gear noise and dynamic load are rarely involved by researchers. The present work examines the complex, nonlinear dynamic behavior of a 6DOF face gear drive system combining with time varying stiffness, backlash, time varying arm of meshing force and supporting stiffness. The mesh pattern of the face gear drive system is analyzed when the modification strategy is applied and the effect of modification on the dynamics response, the time varying arm of meshing force based on the TCA is deduced. The dynamic responses of the face gear drive system show rich nonlinear phenomena. Nonlinear jumps, chaotic motions, period doubling bifurcation and multiple coexisting stable solutions are detected but different from the spur and bevel gear dynamics, which don’t occur near primary and higher harmonic resonance.     

计及短周期误差的直齿轮副近周期运动及其辨识

齿轮副中的齿距偏差等短周期误差使系统出现复杂的周期运动, 影响齿轮传动的平稳性. 将该类复杂周期运动定义为近周期运动, 采用多时间尺度Poincaré映射截面对其进行辨识. 为研究齿轮副的近周期运动, 引入含齿距偏差的直齿轮副非线性动力学模型, 并计入齿侧间隙与时变重合度等参数. 采用变步长4阶Runge-Kutta法数值求解动力学方程, 由所提出的辨识方法分析不同参数影响下系统的近周期运动. 根据改进胞映射法计算系统的吸引域, 结合多初值分岔图、吸引域图与分岔树状图等研究了系统随扭矩与啮合频率变化的多稳态近周期运动. 研究结果表明, 齿轮副中的短周期误差导致系统的周期运动变复杂, 在微观时间尺度内, 系统的Poincaré映射点数呈现为点簇形式, 系统的点簇数与实际运动周期数为宏观时间尺度的Poincaré映射点数. 短周期误差导致系统在微观时间尺度内的吸引子数量增多, 使系统运动转迁过程变复杂. 合理的参数范围及初值范围可提高齿轮传动的平稳性. 该辨识与分析方法可为非线性系统中的近周期运动研究奠定理论基础.      

齿轮系统非线性振动研究进展

围绕圆柱齿轮系统的参数振动和间隙非线性振动问题, 较为详细地评述了20年来国 际上的研究进展情况. 文中首先说明了齿轮系统啮合过程非线性振动的基本概念, 包括基本 的力学模型、数学模型、不同类型的分析系统和求解方法; 然后分别评述了时变轮齿啮合刚 度参数振动问题和齿侧间隙非线性振动问题的研究进展. 此后讨论了同时 包含齿侧间隙和时变啮合刚度时齿轮非线性振动问题方面的研究. 最后,建议了齿轮系统 非线性振动方面今后的研究重点.     

Planetary gearbox with localised bearings and gears faults: simulation and time/frequency analysis

Planets bearings of planetary gear sets exhibit high rate of failure; detection of these faults which may result in catastrophic breakdowns have always been challenging. The objective of this paper is to investigate the planetary gears vibration properties in healthy and faulty conditions. To seek this goal a previously proposed lumped parameter model (LPM) of planetary gear trains is integrated with a more comprehensive bearing model. This modified LPM includes time varying gear mesh and bearing stiffness and also nonlinear bearing stiffness due to the assumption of Hertzian contact between the rollers/balls and races. The proposed model is completely general and accepts any inner/outer race bearing defect location and profile in addition to its original capacity of modelling cracks and spalls of gears; therefore, various combinations of gears and bearing defects are also applicable. The model is exploited to attain the dynamic response of the system in order to identify and analyze localized faults signatures for inner and outer races as well as rolling elements of planets bearings. Moreover, bearing defect frequencies of inner/outer race and ball/roller and also their sidebands are discussed thoroughly. Finally, frequency response of the system for different sizes of planets bearing faults are compared and statistical diagnostic algorithms are tested to investigate faults presence and growth.     

齿轮箱非线性耦合系统的动力学分析

分别建立了啮合齿轮子系统弯扭耦合振动模型、弹性轴子系统的弯曲振动和扭转振动模型以及齿轮箱弹性箱板子系统的横向振动模型,通过轴承多维刚度矩阵和子结构之间的受力变形协调关系将各子结构的振动模型联立起来,从而得到整个齿轮箱耦合系统的动力学模型。结合相图和庞加莱映射图分析了系统的运动特性,采用功率流方法研究了系统振动能量传递特性及其影响因素,揭示了外部激励和轴承刚度等因素对系统特性的影响,为齿轮箱系统的振动控制与结构设计提供了新的分析方法和理论依据。     

Modeling and analyzing of torsional dynamics for helical gear pair considered double and three teeth drive-side meshing

Helical gears are generally considered to be more stable than spur gears. But rattling of the helical gear transmission is found in the engineering practice. The torsional dynamics equations of helical gear pair in high-speed railway gearbox are established in order to reveal the rattling mechanism of helical gear transmission. Double and three teeth pair drive-side meshing are considered. The multi-state meshing zone, load distribution rate and time-varying stiffness determined by contact ratio are analyzed and calculated. The dynamic characteristic transition process of the system is analyzed according to the bifurcation diagrams and the corresponding top Lyapunov exponent (TLE) diagrams, phase portraits, Poincaré maps and time history spectrums of dynamic meshing force based on the calculation of these parameters. The tooth disengagement, tooth back-side contact and their parameter range are found. This study can provide theoretical basis for rattling suppression and transmission stability improvement of helical gear pair.

     

Effect of non-linearities in the identification and fault detection of gear-pair systems

This study investigates issues related to parametric identification and health monitoring of dynamical systems with non-linear characteristics. In the first part, a gear-pair system supported on bearings with rolling elements is selected as an example mechanical model and the corresponding equations of motion are set up. This model possesses strongly non-linear characteristics, accounting for gear backlash and bearing stiffness non-linearities. Then, the basic steps of the parametric identification and fault detection procedure employed are outlined briefly. In particular, a Bayesian statistical framework is adopted in order to estimate the optimal values of the gear and bearing model parameters. This is achieved by combining experimental information from vibration measurements with theoretical information built into a parametric mathematical model of the system. In the second part of the study, characteristic numerical results are presented. First, based on the effect of the system parameters on its dynamics, a solid basis is created for explaining some of the peculiar results obtained by applying classical gradient-based optimization methodologies for the strongly non-linear system examined. Some serious difficulties, associated with the existence of irregular response or the coexistence of multiple motions, are first pointed out. A solution to some of these problems, through the application of a suitable genetic algorithm, is then presented. Special problems, related to more classical identification issues associated with the presence of measurement noise and model error, are also investigated.     

Effect of spalling or tooth breakage on gearmesh stiffness and dynamic response of a one-stage spur gear transmission

Tooth faults affecting gear transmission are always accompanied by a stiffness reduction. In this article an analytical method is proposed to quantify the reduction of gearmesh stiffness due to two common tooth faults: spalling and breakage. Bending, fillet-foundation and contact deflection are taken into account. The dynamic response of a single stage spur gear transmission is computed by using analytical gearmesh issued from analytical modelling and the vibration signatures of each tooth fault is identified.     

Dynamic features of planetary gear set with tooth plastic inclination deformation due to tooth root crack

Gear tooth root crack, as one of the popular gear tooth failures, is always caused by the dynamic load or excessive load applied to the tooth. It will devastate the working performance of the gear system, by problems such as vibration and noise, or even lead to a broken tooth, which will stop the normal working process of the gear system. It has attracted wide attention from researchers. However, the previous studies focused their concentration only on the mesh stiffness reduction due to tooth root crack, while the tooth plastic inclination due to tooth bending damages like gear tooth root crack is seldom considered. In this paper, a tooth plastic inclination model for spur gear with tooth root crack is developed by regarding the cracked tooth as a cantilever beam. It influences not only the displacement excitation but also the mesh stiffness and load-sharing factor among tooth pairs in mesh. The simulation results obtained by incorporating the tooth plastic inclination deformation model together with the tooth root crack model into a 21-Degree-of-Freedom planetary gear dynamic model indicate that the tooth plastic inclination has a significant effect on the performance of the gear system rather than the mesh stiffness reduction due to tooth root crack.     

Theoretical analysis of nonlinear vibration characteristics of gear pair with shafts

The circumferential vibration of a gear pair is a parametric excitation caused by nonlinear tooth stiffness, which fluctuates with meshing. In addition, the vibration characteristics of the gear pair become complicated owing to the tooth profile error and backlash. It is considered that the circumferential vibration of the gear pair is affected by the torsional vibration of the shafts. It is important to understand quantitatively the vibration characteristics of the gear system considering the shafts. Therefore, the purpose of this research was to clarify the nonlinear vibration characteristics of a gear pair considering the influence of the shafts using theoretical methods. To achieve this objective, calculations were performed using equations of motion in which the circumferential vibration of the gear pair and the torsional vibration of the shafts were coupled. The nonlinear tooth stiffness was represented by a sine wave. The influence of tooth separation was considered by defining a nonlinear function using backlash and the tooth profile error. For the numerical calculations, both stable and unstable periodic solutions were obtained by using the shooting method. The effect of the shafts on the gear system vibration were clarified by comparing the results in the cases in which the shaft was not considered, one shaft was considered, and both shafts were considered.     

航空发动机整机耦合动力学模型及振动分析

面向航空发动机整机振动, 建立了航空发动机转子-滚动轴承-机匣耦合动力学模型. 该模型具有如下特点: (1)考虑转子、滚动轴承及机匣之间的耦合作用; (2)考虑了实际航空发动机的弹性支承及挤压油膜阻尼效应; (3)将转子考虑为等截面自由欧拉梁模型, 运用模态截断法进行分析; (4)考虑了滚动轴承间隙、非线性赫兹接触力以及变柔性VC(Varyingcompliance)振动; (5)考虑了转子与机匣之间的碰摩故障. 运用数值积分方法研究了航空发动机的整机振动规律, 包括: 滚动轴承VC振动分析、弹性支承刚度对耦合系统临界转速的影响、转轴模态截断阶数NM对系统响应的影响分析、挤压油膜阻尼器参数对系统响应的影响分析、突加不平衡的瞬态响应分析以及转静碰摩故障特性分析等.      

Ride dynamics mathematical model for a single station representation of tracked vehicle

Tracked vehicles are exposed to severe ride environment due to dynamic terrain-vehicle interactions. Hence it is essential to understand the vibration levels transmitted to the vehicle, as it negotiates different types of terrains at different speeds. The present study is focused on the development of single station representation of tracked vehicles with trailing arm hydro-gas suspension systems, simulating the ride dynamics. The kinematics of hydro-gas suspension system have been derived in order to determine the non-linear stiffness characteristics at various charging pressures. Then, incorporating the actual suspension kinematics, non-linear governing equations of motion have been derived for the sprung and unsprung masses and solved by coding in Matlab. Effect of suspension non-linear dynamics on the single station ride vibrations have been analyzed and validated with a multi-body dynamics model developed using MSC.ADAMS. The above mathematical models would help in estimating the ride vibration levels of the tracked vehicle, negotiating different types of terrains at various speeds and also enable the designers to fine-tune the suspension characteristics such that the ride vibrations are within acceptable limits. The mathematical ride model would also assist in development of non-linear ride vibration model of full tracked vehicle and estimate the sprung mass dynamics.     

Nonlinear behavior analysis of geared rotor bearing system featuring confluence transmission

In this paper, the nonlinear vibration characteristics of geared rotor bearing system and the interactions among gears, shafts, and plain journal bearings were studied. First, with the consideration of backlash, transmission error, time-varying mesh stiffness, and layout parameters, the dynamic model of geared rotor bearing system featuring confluence transmission was proposed. The nonlinear oil-film forces were computed with the Reynolds equation for finite-length journal bearings. Second, the responses of meshing vibration and bearing vibration were discussed. The numerical results revealed that the system exhibited a diverse range of periodic, sub-harmonic, and chaotic behaviors. Under different ranges of rolling frequency, the system got into chaos state through different roads. Moreover, in lower frequency, meshing vibration showed coexist of different periodic motions. Lastly, couplings of nonlinear oil-film force and nonlinear gear mesh force were discussed through a range of rolling frequencies. Gear-bearing dynamic interactions were demonstrated through the analysis of dynamic gear loads and dynamic bearing loads, and the coupling effect behaved different when rolling frequency changed.     

Study of milling stability with Hertz contact stiffness of ball bearings

This present work examines the stability and nonlinear responses of a spindle milling system supported by ball bearings. A shaft finite element based on Timoshenko beam theory is employed to model the spindle, and modal reduction method is therefore adopted for saving the numerical calculating time. The issues of evaluating the effects of the ball bearing Hertz contact stiffness are consequently addressed. It is found that suitable constant bearing stiffness can be adopted to replace the nonlinear nonsmooth Hertz stiffness in prediction of the critical cutting depth of the milling system in certain bearing configuration conditions. For the constant bearing stiffness can be obtained by experiment, this replacement will undoubtedly simplify the spindle-bearing milling system. But with the increase in the bearing clearance, the spindle milling system will present obvious nonlinear behaviors, and the nonlinear Hertz contact bearing stiffness will take over. Isolated islands of chatter vibration, which are induced by the nonlinear nonsmooth bearing Hertz stiffness, can be found exist in milling processes in large bearing clearance conditions.     

An enhanced multi-term harmonic balance solution for nonlinear period-one dynamic motions in right-angle gear pairs

A nonlinear time-varying dynamic model for right-angle gear pair systems, considering both backlash and asymmetric mesh effects, is formulated. The mesh parameters that are characteristically time-varying and asymmetric include mesh stiffness, directional rotation radius and mesh damping. The period-one dynamic motions are obtained by solving the dimensionless equation of gear motion using an enhanced multi-term harmonic balance method (HBM) with a modified discrete Fourier Transform process and the numerical continuation method. The accuracy of the enhanced HBM solution is verified by comparison of its results to the more computational intensive, direct numerical integration calculations. Also, the Floquet theory is applied to determine the stability of the steady-state harmonic balance solutions. Finally, a set of parametric studies are performed to determine quantitatively the effects of the variation and asymmetry in mesh stiffness and directional rotation radius on the gear dynamic responses.     

An analytical determination of speed factor in gear designs

In practical gear design, the “speed factor” is usually employed which is defined as a ratio of the allow-able stress at required running speed of the gear system to the stress at zero speed. At present, several expressions for the speed factor are recommended by several authorities; however, those are almost all empirical and not analytical. The present paper aims to contribute to an analytical determination of the speed factor for spur gears as stated below. First, from a dynamic photoelastic test of a pair of spur gears, the following results were obtained:

1. (1)
   At a contant speed and torque and at the same point of engagement, the maximum fillet stress did not have a specific constant value but had somewhat scattered values due to the vibration of gear system under operation.     
   
   

Global bifurcation and chaos analysis in nonlinear vibration of spur gear systems

The global homoclinic bifurcation and transition to chaotic behavior of a nonlinear gear system are studied by means of Melnikov analytical analysis. It is also an effective approach to analyze homoclinic bifurcation and detect chaotic behavior. A generalized nonlinear time varying (NLTV) dynamic model of a spur gear pair is formulated, where the backlash, time varying stiffness, external excitation, and static transmission error are included. From Melnikov method, the threshold values of the control parameter for the occurrence of homoclinic bifurcation and onset of chaos are predicted. Additionally, the numerical bifurcation analysis and numerical simulation of the system including bifurcation diagrams, phase plane portraits, time histories, power spectras, and Poincare sections are used to confirm the analytical predictions and show the transition to chaos.     

3D Dynamic Modelling of Spatial Geared Systems

In this paper, a nonlinearly dynamic model for a spatial geared systemwith intersecting-axes, which consists of bevel gears, bearings, andshafts, is proposed based on a specific finite element theory. A newtype of spatial gear element which is consistent with the specific finiteelement theory is developed and completely describes all thedeformations that exist for the spatial motions of a pair of bevel gears,the time-variant meshing stiffness, and various types of gear errors inmanufacturing and assembly. The 3D motions of the spatial geared systemin axial, lateral, and torsional directions are coupled in the model. Theproposed approach has been coded into a software system and a dynamicanalysis for the spatial geared system is carried out. The nonlinearinfluences of axial, lateral and torsional stiffnesses of the shaft onthe vibration of the spatial geared system are especially investigated.The lateral stiffness changes the resonance peak frequencies of thespatial geared system and the torsional stiffness greatly affects thesize of the dynamic load and vibration amplitude.