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.     

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 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.     

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.     

Influence of manufacturing errors on dynamic floating characteristics for herringbone planetary gears

Owing to the present of manufacturing errors, the dynamic floating characteristics of herringbone planetary gear train (HPGT) can be changed in comparison with the original ideal design. In this research, based on the actual structure of herringbone gears, taking into consideration manufacturing eccentric errors and tooth profile errors, bearing deformation, time-varying meshing stiffness, gyroscopic effect, and so on, a novel and generalized bending–torsional–axial coupled dynamic model of a herringbone planetary gear train is presented to investigate the dynamic floating performances applying the lumped-parameter approach. The model is capable of being employed for the vibration behavior analysis of the HPGT with different types of manufacturing errors and arbitrary number of planets. The variable step Runge–Kutta algorithm is utilized to compute the dynamic responses of the HPGT system. In combination with the proposed computational approach of the component floating displacement amount, the relationship among manufacturing errors, component floating displacements, and different floating forms is obtained, and the effects of manufacturing errors on the HPGT dynamic floating performances are discussed. Meanwhile, sun gear radial floating trajectories in two cases of sun gear float and non-float are compared and analyzed. Results indicate that the manufacturing error and component float prominently affect the dynamic floating characteristics in the HPGT system.     

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。     

Stochastic Vibration Model of Gear Transmission Systems Considering Speed-Dependent Random Errors

A dynamic and stochastic simulation model is developed for analyzing the vibration of gear transmission systems with consideration of the influence of the time-variant stiffness, loads, and gear transmission errors. The gear transmission system is viewed as a non-linear, time-correlated and stationary stochastic system. The transmission errors of gears are decomposed into harmonic and random components based on the spectral analysis. To simulate the random component, a second order Markov process with time-variant parameters considering influence of rotational speed is proposed and the method to determine the model parameters based on the random error of measured gear transmission error is developed. A simulation system is developed. The input to the simulation system is a white Gaussian noise process and harmonic errors, and the output is the rotational vibration acceleration of gears. Experiments are carried out to verify the proposed model. The influences of the random error on vibration acceleration are examined using the developed simulation system.     

Coupled bending and torsional vibration of nonsymmetrical axially loaded thin-walled Bernoulli–Euler beams

The dynamic transfer matrix is formulated for a straight uniform and axially loaded thin-walled Bernoulli–Euler beam element whose elastic and inertia axes are not coincident by directly solving the governing differential equations of motion of the beam element. Bernoulli–Euler beam theory is used, and the cross section of the beam does not have any symmetrical axes. The bending vibrations in two perpendicular directions are coupled with torsional vibration and the effect of warping stiffness is included. The dynamic transfer matrix method is used for calculation of exact natural frequencies and mode shapes of the nonsymmetrical thin-walled beams. Numerical results are given for a specific example of thin-walled beam under a variety of end conditions, and exact numerical solutions are tabulated for natural frequencies and solutions calculated by the other method are also tabulated for comparison. The effects of axial force and warping stiffness are also discussed.     

Computational approach to design face-milled spiral bevel gear drives with favorable conditions of meshing and contact

The micro-geometry of the tooth surfaces of spiral bevel and hypoid pinions has to be fine-adjusted to obtain enhanced meshing and contact characteristics during the meshing process with their corresponding mating gears. In this paper, a new methodology is proposed to design face-milled spiral bevel gear drives to, firstly, derive favorable orientation and dimensions of the contact pattern between the mating surfaces of the gears and, secondly, obtain a predesigned parabolic function of negative transmission errors with limited magnitude of maximum transmission errors. The proposed approach is based on the definition of the desired topography for the active surfaces of the pinion followed by a numerical derivation of their finishing machine-tool settings through a bound-constrained optimization algorithm. Increasing mechanical strength and reducing the levels of noise and vibration of face-milled spiral bevel gear drives constitute the main objectives of the proposed design process. A numerical example is provided to illustrate the applicability of the developed theory .     

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.     

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.

     

The mathematical phenomenological mapping in non-linear dynamics of spur gear pair and radial ball bearing due to the variable stiffness

In this paper the philosophy of mathematical phenomenological mapping has been applied to the non-linear dynamics of spur gears and radial ball bearings. The spur gear pair dynamics and rolling element bearing dynamics are analyzed separately, but with a tendency to reduce the both of the systems to the same mathematical model. The different reasonable assumptions are taken in every of these analyzes, but they do not have significant influence to the accuracy of the results. The systems are reduced to the single degree of freedom dynamics model. The total gear stiffness and ball bearing stiffness are recognized as the main influent factor of vibration behavior of these machine elements. Therefore, the special attention was paid to the new approach and procedure for stiffness solving and related problems. A single spur gear pair dynamics is solved and the results for total gear stiffness and vibration are shown. The conclusions emphasize the importance of described parallel analyzes in order to reduce the calculation time in solving different phenomena with usage of the principle of mathematical phenomenology.     

An investigation on lateral and torsional coupled vibrations of high power density PMSM rotor caused by electromagnetic excitation

Electromagnetic excitation in high power density permanent magnet synchronous motors (PMSMs) due to eccentricity is a significant concern in industry; however, the treatment of lateral and torsional coupled vibrations caused by electromagnetic excitation is rarely addressed, yet it is very important for evaluating the stability of dynamic rotor vibrations. This study focuses on an analytical method for analyzing the stability of coupled lateral/torsional vibrations in rotor systems caused by electromagnetic excitation in a PMSM. An electromechanically coupled lateral/torsional dynamic model of a PMSM Jeffcott rotor is derived using a Lagrange–Maxwell approach. Equilibrium stability was analyzed using a linearized matrix of the equation describing the system. The stability criteria of coupled torsional–lateral motions are provided, and the influences of the electromagnetic and mechanical parameters on mechanical vibration stability and nonlinear behavior were investigated. These results provide better understanding of the nonlinear response of an eccentric PMSM rotor system and are beneficial for controlling and diagnosing eccentricity.     

Spectral finite element of a helix

Determination of a spectral (i.e. frequency dependent) finite element of a helix is the focus of this communication. The helix is treated as straight, linear elastic element, exhibiting coupling of axial with torsional responses. We derive explicit forms of all the coefficients of the stiffness matrix and plot their dependencies on the frequency and the parameter describing the said coupling. In general, the growth of that parameter leads to a progressively denser occurrence of the resonances of both axial and torsional motions.     

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.     

Passive control of vibration of thin-walled gears: advanced modelling of ring dampers

Vibrations on gears are mainly induced by the gear mesh contact. Resonance conditions of the gear may occur during service if the mesh frequency is close to the natural frequencies of the system at the designed speed of the shaft. Since detuning is not always possible in gears, the response level must be reduced by increasing the damping of the system. In this paper, a passive approach based on the application of a ring damper to reduce the vibration level is presented. The ring damper is placed in a groove underneath the outer rim of the gear. The contact is guaranteed by the preload due to the elasticity of the ring damper itself and above all by the centrifugal force that presses the damper against the groove during rotation. The relative motion of the two components at the contact interface dissipates energy by friction, and hence damping is generated. The vibration amplitude is reduced by optimizing the material and geometrical properties of the ring damper. One of the most important parameters in the determination of the amount of damping due to friction phenomena is the static normal load at the contact, which depends on the mass, the shape, and the material of the ring damper. A numerical method is presented, which couples the static and dynamic equilibrium equations of the assembly. The core of the proposed method is the contact element that takes into account local stick–slip–lift off of the contact and determines the contact forces in terms of static and dynamic loads, which are then used to solve the coupled static and dynamic equilibrium. Since the ring damper has a cut that breaks its continuous circular shape in order to be fitted on the groove, the hypothesis of cyclic symmetry for the gear/ring–damper assembly fails. As a consequence, an appropriate reduced-order modeling is presented to allow the forced response calculations. The algorithm is applied to a dummy bevel gear and to a ring damper having a flat punch contact area. The forced response calculations are performed to highlight the nonlinear interaction between the gear and damper by varying the parameters that mainly affect the amount and distribution of the contact forces and therefore the response level.     

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.     

含裂纹梁非线性静动力特性及简化动力学建模Static and dynamic behaviour of cracked beam and simplified dynamic model

主要研究裂纹对梁结构动力特性的影响规律,进而为含裂纹梁结构状态监测提供理论依据。首先,对裂纹影响区域进行分析,建立含裂纹梁二维接触非线性有限元模型,阐明含裂纹梁具有拉压不同刚度的静力特性;其次,通过对机理模型的分析,指出拉压不同刚度会引起轴向与弯曲的耦合振动;然后,通过非线性动力学分析方法研究其动力特性,观察到含裂纹梁在冲击荷载下会产生轴向与弯曲的耦合振动现象,并指出这种轴向与弯曲耦合振动的一个重要特征是轴向振动频谱图中含有弯曲振动基频的两倍频成分;最后,通过引入非线性弹簧建立一种新颖的含裂纹梁简化动力学模型,通过与精细有限元分析对比,验证了模型的合理性。该简化动力学模型将接触非线性问题转换为材料非线性问题,避免了费时的接触非线性动力学求解过程。     

An enhanced multi-term harmonic balance solution for nonlinear period-\varvec{\beta } dynamic motions in right-angle gear pairs

A nonlinear, time-varying dynamic model for right-angle gear pair systems is formulated to analyze the existence of sub-harmonics and chaotic motions. This pure torsional gear pair system is characterized by its time-varying excitation, clearance, and asymmetric nonlinearities as well. The period-1 dynamic motions of the same system were 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 presented in another paper by the authors. Here, the sub-harmonics and chaotic motions are studied using the same solution technique. The accuracy of the enhanced multi-term HBM is verified by comparing its results to the solutions obtained using the more computational intensive direct numerical integration method. Due to its inherent features, the enhanced multi-term HBM cannot predict the chaotic motions. However, the frequency ranges where chaotic motions exist can be predicted using the stability analysis of the HBM solutions. Parametric studies reveal that the decrease in drive load or the increase of kinematic transmission error (TE) can result in more complex gear dynamic motions. Finally, the frequency ranges for sub-harmonics and chaotic motions, as a function of TE and drive load, are obtained for an example case.     

某重型车床横向进给系统传动刚度分析与实验研究

进给伺服系统的性能对数控机床的跟踪及定位精度、加工表面质量等有着重要的作用。针对某重型车床的横向进给系统,综合考虑了轴的扭转刚度、齿轮的啮合刚度、丝杠螺母副接触刚度和丝杠支承轴承的轴向刚度等因素,建立了等效单自由度力学模型,分析刚度因素对工作台输出行为的影响。通过仿真计算分析了中间传动链各个刚度环节对工作台综合刚度的贡献量,找出了传动链的刚度薄弱环节。现场实验测试了工作台不同进给位置下的临界爬行速度,得到了临界爬行速度与丝杠的轴向刚度的关系,理论分析与实验结果相吻合。所得结论为该重型车床横向进给系统的优化设计提供了理论支持。