Nonlinear Dynamics and Vibration of Gear and Bearing Systems using A Finite Element/Contact Mechanics Model and A Hybrid Analytical-Computational Model

This work investigates the dynamics and vibration in gear systems, including spur and helical gear pairs, idler gear trains, and planetary gears. The spur gear pairs are analyzed using a finite element/contact mechanics (FE/CM) model. A hybrid analytical-computational (HAC) model is proposed for nonlinear gear dynamics. The HAC predictions are compared with FE/CM results and available experimental data for validation.

Chapter 2 investigates the static and dynamic tooth root strains in spur gear pairs using a finite element/contact mechanics approach. Extensive comparisons with experiments, including those from the literature and new ones, confirm that the finite element/contact mechanics formulation accurately predicts the tooth root strains. The model is then used to investigate the features of the tooth root strain curves as the gears rotate kinematically and the tooth contact conditions change. Tooth profile modifications are shown to strongly affect the shape of the strain curve. The effects of strain gage location on the shape of the static strain curves are investigated. At non-resonant speeds the dynamic tooth root strain curves have similar shapes as the static strain curves. At resonant speeds, however, the dynamic tooth root strain curves are drastically different because large amplitude vibration causes tooth contact loss. There are three types of contact loss nonlinearities: incomplete tooth contact, total contact loss, and tooth skipping, and each of these has a unique strain curve. Results show that different operating speeds with the same dynamic transmission error can have much different dynamic tooth strain.

Chapters 3, 4, and 5 develops a hybrid-analytical-computational (HAC) method for nonlinear dynamic response in gear systems. Chapter 3 describes the basic assumptions and procedures of the method, and implemented the method on two-dimensional vibrations in spur gear pairs. Chapters 4 and 5 extends the method to two-dimensional multi-mesh systems and three-dimensional single-mesh systems.

Chapter 3 develops a hybrid analytical-computational (HAC) model for nonlinear dynamic response in spur gear pairs. The HAC model is based on an underlying finite element code. The gear translational and rotational vibrations are calculated analytically using a lumped parameter model, while the crucial dynamic mesh force is calculated using a force-deflection function that is generated from a series of static finite element analyses before the dynamic calculations. Incomplete tooth contact and partial contact loss are captured by the static finite element analyses, and included in the force-deflection function. Elastic deformations of the gear teeth, including the tooth root strains and contact stresses, are calculated. Extensive comparisons with finite element calculations and available experiments validate the HAC model in predicting the dynamic response of spur gear pairs, including near resonant gear speeds when high amplitude vibrations are excited and contact loss occurs. The HAC model is five orders of magnitude faster than the underlying finite element code with almost no loss of accuracy.

Chapter 4 investigates the in-plane motions in multi-mesh systems, including the idler chain systems and planetary gear systems, using the HAC method that introduced in Chap. 3. The details of how to implement the HAC method into those systems are explained. The force-deflection function for each mesh is generated individually from a series of static finite element analyses before the dynamic calculations. These functions are used to calculated the dynamic mesh force in the analytical dynamic analyses. The good agreement between the FE/CM and HAC results for both the idler chain and planetary gear systems confirms the capability of the HAC model in predicting the in-plane dynamic response for multi-mesh systems. Conventional softening type contact loss nonlinearities are accurately predicted by HAC method for these multi-mesh systems.

Chapter 5 investigates the three-dimensional nonlinear dynamic response in helical gear pairs. The gear translational and rotational vibrations in the three-dimensional space are calculated using an analytical model, while the force due to contact is calculated using the force-deflection. The force-deflection is generated individually from a series of static finite element analyses before the dynamic calculations. The effect of twist angle on the gear tooth contact condition and dynamic response are included. The elastic deformations of the gear teeth along the face-width direction are calculated, and validated by comparing with the FE/CM results.