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A gear transmission dynamic model for the gear dynamic contact loading, dynamic contact stress
state and dynamic contact strain state analysis is presented. A dynamic model of the transmission with
four degrees of freedom is used. The transmission is analyzed using nonlinear finite elements contact
formulation, using a novel software modules developed by the author used for the generalized analysis of
the geared transmissions in the environment of the open source finite elements framework CODE-ASTER/
SALOME.
2011 Journal of Mechanical Engineering. All rights reserved.
Keywords: stress and strain state analysis, tensor invariants, finite element method, geared
transmissions
finite element models for dynamic response are Based on the results of the experiments
rare because they require a significant computa- conducted during the gear vibration research, it is
tional effort. This is accomplished by many possible to conclude that the excitation is restored
time steps required for the transient response to every time when a new pair of teeth enters
diminish, so that steady state data can be obtained. the mesh. Vibrations with natural frequencies
This study attempts to fill this gap with a general dominate the vibration spectrums. The internal
finite element formulation that can be used for full dynamic forces in teeth mesh, vibration and
gearbox dynamic analyses. noise are consequences of the: change in teeth
Dynamic transmission error is taken as the deformation, teeth impact, gear inertia due to
parameter for the modelling of noise in geared measure and teeth shape deviation [12].
transmission. In the last two decades there is plenty Paper [13] presents two models of the
of work has been concentrating on modelling geared transmission with two or more shafts. The
of the dynamic transmission error for spur and first approach gives a model based on the rigid
helical gears and representing the influence of the rotors coupled with rigid gear teeth, with mass
dynamic transmission errors on the level of noise distributions not balanced and in the form of the
in the geared transmission. Lately, there have been mass particles as the series of the mass debalances
several experiments conducted in order to isolate of the gears in multistep gear transmission. By
particular noise effects like noise coming from a very simple model it is possible to conduct a
bearing, housing noise, meshing action noise and useful investigation of the nonlinear dynamics
backlash noise simply by measuring the dynamic of the multistep gear transmission and nonlinear
phenomena in free and forced dynamics.
transmission error. Some of the earliest models are
This model is suitable to explain source of
represented in [4] and [5].
vibrations and big noise, as well as no stability
For different analysis purposes, there
in gear transmission dynamics. Layering of the
are several modelling choices such as a simple
homoclinic orbits in phase plane is a source of
dynamic factor model, compliance tooth model,
a sensitive dependence on the nonlinear type of
torsional model, and geared rotor dynamic
regime of gear transmission system dynamics.
model, [6]. Using the free vibration analysis
The second approach gives a model based on the
critical para-meters such as natural frequencies
two-step gear transmission taking into account
and vibration modes that are essential for almost
the deformation and creeping as well as visco-
all dynamic investigations can be calculated. elastic teeth gears coupling. Our investigation
The free vibration properties are very useful for was focused on a new model of the fractional
further analyses of planetary gear dynamics, order dynamics of the gear transmissiont. For
including eigen-sensitivity to design parameters, this model we obtained analytical expressions
natural frequency veering, planet mesh phasing, for the corresponding fractional order modes like
and parametric instabilities from mesh stiffness one frequency eigen vibrational modes. Genera-
variations, [7] and [8]. It is also necessary to lization of this model to the similar model of the
systematically study natural frequency and multistep gear transmission is quite simple.
vibration mode sensitivities and their veering The model in this paper represents a typical
characters to identify the parameters critical transmission model with three shafts. Starting with
to gear vibration. In addition, practical gears the first gear pair, a meshing action is observed for
may be mistuned by mesh stiffness variation, all gear meshes simultaneously using no additional
manufacturing imperfections and assembling assumptions concerning the gear geometry or the
errors. For some symmetric structures, such as meshing action boundary and load conditions. The
turbine blades, space antennae, and multispan boundary conditions on the gear-shaft connections
beams, small disorders may dramatically change are assumed to be equal to zero. The internal
the vibration, [9]. The following articles [10] and dynamic forces are obtained as a result of the
[11], related to the nonlinear analysis of dynamic first step of the nonlinear quasi-static analysis
behavior of gears, using experimental methods and are taken as an input for further analysis.
and the application of FEM. The procedure described can be modified for the
Dynamic Model for the Stress and Strain State Analysis of a Spur Gear Transmission 57
Strojniki vestnik - Journal of Mechanical Engineering 58(2012)1, 56-67
purpose of calculation of different types of geared load as inner dynamic load is taken as an
systems simply by combining different steps in input value obtained in a) and approximated
the described analysis and different configurations using harmonic function, as it is described in
of the gears and shafts. It is optional which of the c).
mentioned steps will be of the highest priority, and The developed software can be modified
depends, of course, of the purpose of the concrete for the purpose of calculation of different types
analysis. of geared systems. It is optional which of the
mentioned steps will be of the highest priority, and
1 FINITE ELEMENT MODEL it depends on the purpose of the concrete analysis.
OF THE SPUR GEAR TRANSMISSION That is not of interest here, and therefore will not
be discussed.
Starting with one gear pair, a meshing The gears analyzed in this paper are the
action is observed using no additional assumptions ones from the deep drilling machine gear set,
concerning the gear geometry or the meshing [14]. The gear geometries are generated using the
action boundary and load conditions. A numeric software developed by the authors, [13] to [19],
experiment is developed simply by using the and adapted for the SALOME platform [40]. The
boundary conditions on the gear-shaft connection, obtained geometries are transferred to SALOME
which are assumed to equal zero. The software mesh generation software and discretized using
that is developed for the purpose of dynamic four node tetrahedral elements there (Fig. 1).
analysis of the gear-boxes can be used to obtain
the following results from such model:
a) forces that arise in gear contact during
the gear meshing action as a result of the
incremental quasi-static series of analysis [8]
to [10], for each meshing action time step,
b) the comprehensive modal analysis for the
gear pair, and
c) the forces obtained in a) will be used further
as an input for the nonlinear dynamic
analysis. For the purpose of this paper, it is
assumed that the obtained force is a harmonic
function and in form:
Fn = Fo sin wt, (1)
Fig. 1. Gear transmission model
where Fo is the resultant force for the
observed meshing action time step, Mesh parameters of the geared system are:
d) Finally, the dynamic analysis of the gear number of nodes: 19209,
meshing action is conducted [10]. The contact number of elements: 102868,
number of elements of shaft 1 (staring from There is no sliding between the teeth during
left hand side): 23618, the meshing action.
number of elements of shaft 2 (middle): The transmission functions in constant
30034, temperature field. All other thermodynamic
number of elements of shaft 3 (right bottom): effects can be neglected.
1586. The proportional damping is used according
Gear geometry parameters are given in to
Table 1.
C = 2 b M + a K.
Displacement boundary conditions (Fig.
2) are set on the shaft-bearing connections The continuum discretization is done
nodes. The displacement boundary conditions on using tetrahedral finite elements with linear
the axial bearing connection nodes are set to be approximation of the finite element geometry.
zero in all degrees of freedom, and for the radial
bearing connection nodes this displacement is set 2 ANALYTIC MODEL OF THE SPUR GEAR
to be zero only in X, Y directions. TRANSMISSION
k12
of the amplitude force distribution in gear mesh. c1, k1 c12
way. 2 c34
F2(t)
into consideration. The following assumptions are 3
made:
It is assumed that the contact is without Fig. 3. A simplified dynamic model of the geared
friction: transmission on Fig. 1
Dynamic Model for the Stress and Strain State Analysis of a Spur Gear Transmission 59
Strojniki vestnik - Journal of Mechanical Engineering 58(2012)1, 56-67
The differential equation [2], [3], [20] to between principal stress and stress invariants in
[22] and [24] of the model in Fig. 3 are: form: o = f( L1, L2, L3). Therefore:
m1
x1 + (c1 + c12 ) x1 c12 x2 + L1 = f ( 1 , 2 , 3 ) = 1 + 2 + 3 = tr( G ), (5)
o 1
= o = o = Co , (11)
K31 K32 K33 S=
2 , (16)
3
or J1 = f ( 1 , 2 , 3 ) = 1 + 2 + 3 = tr ( S ) ,
o o J 2 = f ( 1 , 2 , 3 ) = 1 2 + 2 3 + 13 =
= =
(17)
(( ) )
xy xz x o xz 1 2
= tr S 2 tr ( S ) ,
y o yz xy yz 2
(12) J 3 = f ( 1 , 2 , 3 ) = 1 2 3 = det ( S ) .
o
= = Co ,
x o xy
Analogue to Eqs. (11) to (13) for the
xy y o
principal stresses, it is possible to obtain the
the system is defined if condition Eq. (13) is equation of the principal strains by solving the
satisfied: system of Eqs. (17) to (19).
The principal strain directions can be
o2 + o2 + o2 = 1. (13) obtained in the following form:
Dynamic Model for the Stress and Strain State Analysis of a Spur Gear Transmission 61
Strojniki vestnik - Journal of Mechanical Engineering 58(2012)1, 56-67
Additional results for strain distribution The given results are input results for the
along the line of contact for each gear par is calculations of principal invariants in each node
given in Fig. 8, and Von Mises stress distribution for each and every element of the presented
along the line of contact for each transmission geared transmission. An example of the principal
gear par and each time step (Fig. 7) together stress and strain direction calculation for the
with distribution of Von Mises stress on the selected nodes in contact is presented in Fig. 9 and
transmission elements for t = 0.02 is presented in corresponding Tables 2 and 3.
Fig. 6.
Work methodology previously tested on
simple examples from literature [7] to [11], [28]
and [30] and obtained a good coincidence of
results.
a)
Dynamic Model for the Stress and Strain State Analysis of a Spur Gear Transmission 63
Strojniki vestnik - Journal of Mechanical Engineering 58(2012)1, 56-67
1.56 1.62 5.10E-02
1.46 2.64 1.09
Fig. 13. Contact strain tensor invariants for the 1.57 1.56 7.13E-03
gear pair 3-4, for t = 0.02
L1 L2 L3
Work methodology previously tested on 3.99E+09 -1.38E+19 -6.89E+27
simple examples from literature [7] to [11], [28]
and [30] and obtained a good coincidence of 1 [Pa] 2 [Pa] 3 [Pa]
results. -2.54E+09 4.47E+08 6.08E+09
Table 3. Component stresses and strains in node: two pair gears, which makes the problem more
2623, principal stress, strain invariants, principal complex.
stresses and principal strains and appropriate Further research should be directed at
principal directions, for t =0.02 studying the effects of mutual dynamic impact
Node: 2623 of teeth in engagement, as well as at including
x [Pa] y [Pa] z [Pa] connection between the shaft and gear into the
2.088E+09 1.229E+09 1.053E+09 dynamic model and the like.
In accordance with the present trend
xy [Pa] xz [Pa] yz [Pa] of application of new materials, like in [36] to
5.508E+07 -3.036E+07 3.852E+07 [39], authors will, in future studies, simulate the
dynamic behavior of a gear made of composite
materials and study the life of the gears at the
1.57 1.57 6.26E-03 cyclic load.
1.57 1.57 5.77E-03 Based on the numerical results, i.e., on
1.59 1.60 3.61E-02 the presented and other diagrams, a general
conclusion can be drawn: stress and strain
L1 L2 L3
distributions in the case of dynamic behavior of
-4.36E+09 -7.46E+18 2.21E+28
toothed gears is in accord with the results from the
1 [Pa] 2 [Pa] 3 [Pa] aforementioned literature. Thus, these results can
-4.97E+09 -1.83E+09 2.44E+09 be taken as relevant for further research.
Dynamic Model for the Stress and Strain State Analysis of a Spur Gear Transmission 65
Strojniki vestnik - Journal of Mechanical Engineering 58(2012)1, 56-67
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Dynamic Model for the Stress and Strain State Analysis of a Spur Gear Transmission 67