Gear Defect Modeling of a Multiple-Stage Gear Train

This study demonstrates the transient and steady state dynamic loading on teeth within a two-stage gear transmission arising from backlash and geometric manufacturing errors by utilizing a nonlinear multibody dynamics software model. Backlash between gear teeth which is essential to provide better lubrication on tooth surfaces and to eliminate interference is included as a defect and a necessary part of transmission design. Torsional vibration is shown to cause teeth separation and double-sided impacts in unloaded and lightly loaded gearing drives. Vibration and impact force distinctions between backlash and combinations of transmission errors are demonstrated under different initial velocities and load conditions. The backlash and manufacturing errors in the first stage of the gear train are distinct from those of the second stage. By analyzing the signal at a location between the two stages, the mutually affected impact forces are observed from different gear pairs, a phenomenon not observed from single pair of gears. Frequency analysis shows the appearance of side band modulations as well as harmonics of the gear mesh frequency. A joint time-frequency response analysis during startup illustrates the manner in which contact forces increase during acceleration