The statistical analysis of the dynamic performance of a gear system considering random manufacturing errors under different levels of machining precision

Abstract

Gear manufacturing error is one of the main sources of vibration and noise in gears; its influence on the dynamic transmission behaviour of gear systems is a research hotspot. In the current study on the effect of the manufacturing errors, the processing methods of the errors are mostly rough or hypothetical, so the analysis results cannot provide high reference value. This paper proposes a distinctive method to analyse the vibration response of helical gears in the presence of random manufacturing errors and modifications. The presented study performs tooth contact analysis (TCA) with the real tooth surface containing the random tooth profile error and the modification and performs loaded tooth contact analysis (LTCA) based on the superposition of the random pitch error and the initial gap between mating teeth obtained by TCA. Furthermore, the dynamic excitations, including time-varying mesh stiffness and meshing impact, are computed using the above-mentioned TCA and LTCA. The processing method for the manufacturing errors in this paper is reasonable and close to the actual situation of gear engagement. Using this proposed method, statistical analysis was carried out under machining accuracy grades 5, 6 and 7 to show the effect of the different distributions of random manufacturing errors on the gear vibration. The analysis results are of practical significance and provide references for the design and vibration control of gear drive systems.

Sources of Excitation and Models for Cylindrical Gear Dynamics: A Review

“…A method to consider friction in the calculation of the mesh stiffness is shown in [87], while its effects as an excitation source are especially evident along the off-line-of-action direction as highlighted in [88,89]. Manufacturing errors not only influence the MTE and hence the STE, but are directly involved in the dynamics as experimentally shown in [90] and more recently in [91], while the effect of shaft balancing, positioning and alignment of the gear pairs has been analyzed in [92]. For helical gears the centroid of the normal force moves across the facewidth causing a shuttling moment [93] which can be a further excitation as can be the electromagnetic forces [94] in the increasing number of electric vehicles, showing that for a comprehensive analysis also secondary phenomena can play an important role as excitation sources.…”

Influence of 3D modification on dynamic characteristics of herringbone gearbox system and vibration reduction design

“…It undertakes the TCA calculation results to determine initial clearance of tooth surface, then determines the normal flexibility matrix of the tooth surface, establishes loaded contact analysis model, and solves nonlinear programming. 26 In this paper, meshing contact of herringbone gear pair is simplified as cross-section loaded contact model of left and right single helical gear pairs along long axis direction of contact ellipse, as shown in Figure 1. Where, i and j represent the center of instantaneous contact ellipse and any discrete point along long axis, w ik represents initial clearance of ellipse center point i before contacting, and w jk represents clearance of tooth surface at any point j before contacting.…”

Meshing Contact Impact Properties of Circular Arc Tooth Trace Cylindrical Gear Based on Rotating Knife Dish Milling Process

“…Hu et al [24] established the dynamic model of the meshing impact considering the contact ratio and obtained meshing stiffness of a single tooth by loaded tooth contact analysis and tooth contact analysis to calculate meshing impact force. Guo and Fang [25] proposed a distinctive method to analyze the vibration response of helical gears in the presence of random manufacturing errors and modifications. Munro et al [26] studied the relationship between outside line meshing and transmission error to derive a quantitative calculation formula.…”