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.     

Dynamic characteristic analysis of spur gear system considering tooth contact state caused by shaft misalignment

The effect of gear contact state change due to shaft misalignment on meshing stiffness is usually neglected in the traditional stiffness calculation model with misalignment error, the further influence mechanism of shaft misalignment on gear dynamic characteristics is also unclear. To address these shortcomings, a new mesh stiffness calculation model with misaligned gear considering the effects of tooth contact state is proposed by combining the improved loaded tooth contact analysis (LTCA) model. Then the effects of tooth contact state changes aroused by shaft misalignment on the meshing stiffness excitation are investigated. Moreover, a dynamic model of the misaligned gear system with 8 degrees of freedom (DOF) is established, and based on which the dynamic characteristics of the gear system are investigated and verified by experiment. The study results indicate that the proposed model can be used to evaluate the stiffness excitation and dynamic characteristics of the misaligned gear system with the tooth contact state taken into consideration. This study can provide a theoretical method for evaluating and identifying shaft misalignment errors.

     

Direct calculation of AGMA geometry factor J by making use of polynomial equations

The available sources and procedures for determination of AGMA geometry factor J are tables, charts and semi-analytical methods. When computerized gear design is considered, usage of tables requires a number of interpolations; usage of charts requires curve fitting; and usage of semi-analytical methods needs a numerical algorithm and may have convergence problems. As an alternative to these, polynomial equations for direct calculation of AGMA geometry factor J are derived for external spur gears. Thus, it is made possible to evaluate the J factor easily and with minimum process time. J factors are determined being independent of the highest point of single tooth contact (HPSTC). Derived equations can be used to calculate the tooth root stresses corresponding to loads acting on any point on the involute tooth profile. Thus, cases where the center distance is increased for providing backlash or for operating the gears at a desired exact center distance can easily be handled by determining the corresponding new HPSTC. A computer program is developed to demonstrate the usage of the derived equations. The method can also be used for determination of the J factors for gears with non-standard proportions.     

磨损与动力学耦合的行星传动齿轮动力学研究

行星齿轮磨损会导致齿轮齿侧间隙非线性增大、传动精度下降、齿面冲击力增大, 进而会导致齿轮传动系统振动加剧, 因此需要对行星齿轮的齿面磨损与动力学耦合特性进行研究. 本文构建了齿轮非线性磨损与考虑齿轮齿侧间隙的非线性动力学耦合计算模型, 对行星传动齿轮磨损动力学特性进行了研究. 首先建立齿轮啮合非线性动力学模型, 获得齿轮运行过程中的非线性啮合力; 进一步将非线性啮合力与齿轮齿面磨损模型相结合, 研究齿轮齿面磨损分布规律; 并根据齿轮磨损后的齿侧间隙对齿面重构, 同时对齿轮动力学模型进行更新; 进而得到行星齿轮传动中动态啮合力和磨损特性的变化趋势, 并获得齿轮传动系统齿轮齿向振动响应. 数值计算结果表明, 行星齿轮磨损导致齿轮在单?双齿交替啮合时产生的冲击增大, 同时太阳轮?行星轮啮合齿对对磨损较为敏感, 齿面啮合条件剧烈恶化, 是造成行星齿轮传动性能退化的主要原因, 本文研究结果为行星齿轮传动系统运行状态评估与可靠性预测提供了理论基础.      

An innovative tooth root profile for spur gears and its effect on service life

An innovative approach to the design of the gear-tooth root-profile, and its effects on the service life is reported in this paper. In comparison with the widely used trochoidal and the recently proposed circular-filleted root profiles, the optimum profile proposed here is a \(G^2\)-continuous curve that blends smoothly with both the involute of the tooth profile and the dedendum circle. Following the AGMA and ISO standards for fatigue loading, the von Mises stress at the critical section and stress distribution along the gear tooth root are studied. The process leading to gear-tooth failure is composed of the crack initiation phase, in number of cycles \(N_i\), and the crack propagation phase, in \(N_p\) cycles. The strain-life (\(\epsilon\)-N) method is employed to determine \(N_i\), where the crack is assumed to initiate at the critical section. Based on the ANSYS crack-analysis module, the effects of \(G^2\)-continuous blending on the stress intensity factor (SIF) are investigated for different crack sizes. Paris’ law, within the framework of Linear Elastic Fracture Mechanics, is used to correlate the SIF with crack size and, further, to determine \(N_p\). The optimum profile provides a significant reduction in SIF and improvement in both \(N_i\) and \(N_p\). Spur gears are made of high-strength steel alloy 42CrMo4, the effects of its properties and surface treatment on service life improvement not being included in this study.     

基于热弹流润滑的双渐开线齿轮温度场研究

针对现有双渐开线齿轮温度场计算模型不考虑油膜润滑影响的问题,根据双渐开线齿轮啮合特点,提出采用“分段法”建立适合双渐开线齿轮的热弹流润滑模型,综合有限元法和热弹流润滑方法对其本体温度进行研究,并以润滑油膜为热源对其瞬时温升进行研究,最后分析了齿腰分阶参数对双渐开线齿轮温度场影响以及与普通渐开线齿轮温度场差异. 结果表明:双渐开线齿轮本体温度沿齿宽方向呈非对称分布,主动轮最高本体温度偏向齿根啮入端,从动轮偏向齿顶啮出端;啮合齿面间的油膜瞬时温升明显高于两齿轮界面温升,且主动轮界面瞬时温升高于从动轮;齿腰分阶参数变化对双渐开线齿轮温度场影响较小;双渐开线齿轮与普通渐开线齿轮的本体温度及齿面瞬时温升区别不大.      

Enhanced model of load distribution along the line of contact for non-standard involute external gears

The presence of undercut at the tooth root, non-equal addendum on pinion and wheel, non-standard tooth height or non-standard center distance may have decisive influence on the load distribution along the line of contact of spur and helical gear teeth. The curve of variation of the meshing stiffness along the path of contact, quite symmetric respect the midpoint of the interval of contact, loses its symmetry for non-standard geometries and operating conditions. As a consequence, the critical contact points for bending and wear calculations may be shifted from their locations for standard gears. In this paper, a non-uniform model of load distribution along the line of contact of standard spur and helical gears, obtained from the minimum elastic potential criterion, has been enhanced to fit with the meshing conditions of the above mentioned non-standard cylindrical gear pairs. The same analytical formulation of the initial model may be used for the non-standard gears by considering appropriate values of a virtual contact ratio, which are also presented in the paper.     

Dynamic behaviour modelling of a flexible gear system by the elastic foundation theory in presence of defects

In this paper a novel approach for modelling a spur gear system using finite element method combined with elastic foundation theory is developed. The pinion is modelled by shaft finite element and the wheel by a three-dimensional finite element. Elastic foundation is utilized to model the gearmesh. The modal analysis showed the presence of lower natural frequency for thin rimmed gear cases susceptible to be excited by the operating running condition. The transmission error is affected by the wheel shape and by the presence of lower natural frequencies. Eccentricity error and tooth crack are also modelled to observe their influence on the dynamics behaviour of the system. It was found that they are responsible of the apparition of an amplitude modulation.     

A Balanced Maximum Fillet Stresses on Normal Contact Ratio Spur Gears to Improve the Load Carrying Capacity Through Nonstandard Gears

This article presents an idea to remove the inequality in maximum fillet stresses developed between pinion and gear of a step up gear drive. This uniform fillet strength of the gear drive can be achieved by using nonstandard pinion and gear with appropriate addendum modifications generated by nonstandard basic racks of respective tooth thickness not equal to 0.5πm at the pitch circle. The influence of gear parameters such as gear ratio, pressure angle, addendum factor, pinion teeth number, and addendum modifications on the maximum fillet stress on the nonstandard pinion and gears of different tooth thickness has been analyzed through finite element method and finally the optimum value of rack tooth thickness coefficients (k _pc and k _gc ) are suggested for the given gear drive (defined by i) that improves the fillet capacity in bending. This study has been extended for various drives like S _std , S _o , S ₊, and S _? drives.     

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.

     

Using Hob Offset to Balance Dynamic Strength in Spur Gears*

An analytical study of the effect of hob offset on dynamic tooth strength of spur gears is presented. The study was limited to equal and opposite offset values applied to the pinion and gear to maintain the standard operating center distance. The analysis presented is performed using a new version of the NASA gear dynamics code DANST.

The operating speed of a transmission has a significant influence on the amount of hob offset required to equalize dynamic stresses in the pinion and gear. In the transmission studied, at low speeds, the optimum hob offset was found to fluctuate within a range. At higher speeds, the optimum value is constrained by the minimum allowed thickness at the tip of the pinion tooth. For gears that must operate over a range of speeds, an average offset value can be used. Spur gears designed with the procedure presented here can have significant improvements in load capacity.     

Mesh stiffness modelling and dynamic simulation of helical gears with tooth crack propagation

Meccanica - In order to identify gear crack failure, modelling the mesh stiffness of a cracked tooth is crucial. In this study, an analytical model of the mesh stiffness for cracked helical gears...     

Effect of mesh phase on wave vibration of spur planetary ring gear

The distinctive wave vibration of a ring gear affected by mesh effect is investigated based on the inherent symmetry of spur planetary gears. Compared to prior analysis, this work mainly examines the forced flexural and extensional vibrations. The superposition principle and the Fourier series are introduced to jointly deal with the wave vibrations. The dynamics of the ring gear shows that the effect of the mesh phase on the wave vibration is mainly embodied by the specific relationships between the tooth number, the planet number, the largest common factor of them, the planets’ circumferential position, and the excited wave numbers in the typical rotational, translational and planet modes. For the equal systems, the three modes can be possibly excited depending on the specific mesh phase. And the dominant vibration orders of them are 0, 1 and 2, respectively. The non-zero lowest order is equal to the largest common factor of the two numbers. But for the diametrical ones, only the first two modes can be excited, and the dominant orders of them are 0 and 1, respectively. And the lowest non-zero wave number is 2 for even tooth number and 1 for odd tooth number. As a typical application, these relationships can be used to predict and suppress some potential wave resonances of the ring gear by optimizing the ring-planet mesh phase. The main results are demonstrated with finite element examples and comparisons with the existing literature.     

Dynamic modeling and analysis of a spur planetary gear involving tooth wedging and bearing clearance nonlinearity

Tooth wedging, also known as tight mesh, occurs when a gear tooth comes into contact on the drive-side and back-side simultaneously. Tooth wedging risks bearing failures from elevated forces. This work studies the nonlinear tooth wedging behavior and its correlation with planet bearing forces by analyzing the dynamic response of an example planetary gear. This planetary gear is representative of a wind turbine geartrain. A two-dimensional lumped-parameter model is extended to include tooth separation, back-side contact, tooth wedging, and bearing clearances. The results show significant impact of tooth wedging on planet bearing forces for a wide range of operating speeds. To develop a physical understanding of the tooth wedging mechanism, connections between planet bearing forces and tooth forces are studied by investigating physical forces and displacements acting throughout the planetary gear. A method to predict tooth wedging based on geometric interactions is developed and verified. The major causes of tooth wedging relate directly to translational vibrations caused by gravity forces and the presence of clearance-type nonlinearities in the form of backlash and bearing clearance.     

Calculation of conformal mapping function of the tooth profile on evolvent gear by computer

The exact solution of the stress and the displacement on spur gear can be gained by the method of conformal mapping of complex variables in plane elasticity. But it is difficult to get the comformal mapping function for the tooth profile with different parameters. They used to be obtained through trial method. This is time-consuming and expensive. In this paper a computer program is drawn up for the conformal mapping function. A large amount of calculation has given proof of its success and of the precision of the mapping function: thereby the main obstacle has been removed for the practical application of the conformal mapping method to the stress and displacement of tooth on evolvent gear.     

Gear tooth stress analysis by the complex potentials method

The complex potentials method of plane elasticity theory is applied to spur gear stress analysis. The concept is that the stress field in a gear tooth loaded by a point force can be obtained using the Boussinesq solution and a transformation function mapping a bell-shaped curve approximating the real tooth shape in the z-plane into the semi-infinite ζ-plane. The main features of an original computer code implementing this formulation are presented along with applications.

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Sommario Dopo un'illustrazione di come lo stato di sollectitazione in un dente di una ruota dentata a denti diritti puo' essere ottenuta mediane il metodo delle trasformazioni conformi e dei potenziali complessi della teoria dell'elasticita' piana, viene presentata la struttura di un codice di calcolo originale che implementa questo approccio ed alcune applicazioni.

     

齿轮接触有限元分析

通过接触仿真分析研究了通用接触单元在轮齿变形和接触应力计算中的应用。建立了一对齿轮接触仿真分析的模型，并使用新的接触单元法计算了轮齿变形和接触应力，与赫兹理论比较，同时也计算了摩擦力对接触应力的影响。计算分析了单元离散、几何、边界范围与加载或约束处理方式的误差，建立了一个计算轮齿变形和接触应力的标准，说明了新的接触单元法的精确法、有效性和可靠性。     

渐开线斜齿轮非稳态弹流润滑数值模拟研究

建立了渐开线斜齿轮啮合的弹流润滑计算模型,将斜齿圆柱齿轮啮合的齿面接触等效为有限长线接触的弹流润滑问题.考虑斜齿轮啮合的实际因素,将斜齿轮啮合过程中的等效曲率半径和齿面载荷的变化反映到弹流润滑计算模型中,应用统一Reynolds方程方法求得轮齿在1个完整啮合周期内的瞬时弹流润滑数值解.结果表明：斜齿轮啮合线上各点处的膜厚、压力均有较大不同,各接触点处的油膜厚度受综合曲率半径的影响较大;斜齿轮传动非稳态效应相对较弱;小齿轮齿根附近和节点位置处润滑状态较差;适当增大压力角可以改善齿轮的润滑.     

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.     

考虑弹流润滑作用的斜齿轮啮合分析方法研究

油膜弹流润滑在齿轮传动中有着非常重要的作用,为得到油膜润滑作用下的齿轮啮合响应,基于ABAQUS/STANDARD的静态计算结果,首先提取了仅有齿轮啮合的齿面接触刚度,再结合油膜刚度得到了齿轮和油膜的综合接触刚度,并以此综合刚度作为接触属性关系进行齿轮的静动态运动响应计算。此外,对齿轮啮合时出现的接触区域(接触斑)不连续现象也进行了分析。最终结果表明考虑油膜润滑作用时,齿轮面的最大接触应力比无润滑作用时下降了30%左右,而齿根处最大拉应力则下降了6.14%。本方法为齿轮动力学分析和齿轮的优化设计提供了基础条件。