Proc.

of the 5th International Conference on Advances in Mechanical Engineering (ICAME-2011), June 06-08, 2011
S.V. National Institute of Technology, Surat 395 007, Gujarat, India

Effect of Time Varying Mesh Stiffness on Natural Frequencies

of Two Stage Spur Gear Speed Reducer
1* 2
R.I. Patel , Prof. S.S. Pathan
1. Pursuing M.E. Mechanical Engg. L.D. College of Engineering, Ahmedabad.
2. Sr. Lecturer in Mechanical Engg. L.D. College of Engineering , Ahmedabad.
*
Corresponding author (e-mail: rip111176@yahoo.com )
Increasing interest of dynamics characteristics of gear system requires numerous
research and efforts to understand the behaviour of gear system. In this paper,
concept of experimental modal analysis is used to derive natural frequencies of
two stage spur gear speed reducer. Dynamic properties (time varying mesh
stiffness, natural frequency) are calculated using MATLAB program for an
undamped two stage gear system. The dynamic simulation model is developed
using equation of motion. Frequency Response Function (FRF) method is used
to derive modal parameters. Time varying mesh stiffness, FRF and change in
natural frequencies are plotted. It is observed that variation in mesh stiffness for
meshing gear pairs plays significant role in functional behaviour of gears.
Predicted natural frequencies are validated through experiments and ANSYS
simulations. FFT Spectrum analyser is used to capture the experimental data.
Mesh stiffness variation, the change in stiffness of meshing teeth as the number
of teeth in contact changes, causes parametric instabilities and severe vibration
in gear systems. Mesh stiffness variation is approximated by Fourier series.
Keywords: Modal analysis; Time Varying Mesh Stiffness; Frequency Response
Function; Speed reducer; FFT Spectrum analyser.
1. Introduction
Recently, there has been increased interest in the dynamic effects in gear systems.
This interest is stimulated by demands for stronger, higher-speed, improved-performance, and
longer-lived systems. This has stimulated numerous research efforts directed toward
understanding gear dynamic phenomena. However, many aspects of gear dynamics are still
not satisfactorily understood.
Vibration and noise reduction is a major concern in power train and gearing
applications. A primary source of gear vibration and noise is the dynamic excitation from the
changing stiffness of the meshing teeth. The mesh stiffness associated with elastic tooth
bending varies as the number of teeth in contact changes. Furthermore, mesh stiffness
variation directly affects tooth deflections and transmission error[1].
The objective of this study is to develop a mathematical model to predict the natural
frequencies in two mesh multi gear system. The two meshes can have different mesh
frequencies, amplitudes of mesh stiffness variation, contact ratios, and mesh phasing. By
ANSYS modal analysis simulation, geometrical model of speed reducer is tested numerically.
Experiments are conducted for validations of results. An approach is given here in order to
explore the importance of time varying mesh stiffness.
Modal data is useful information helps the designer to identify the areas of weakness
in design of a structure. The calculation can be performed without actually having to physically
modify the structure until a suitable set of design is achieved. All vibration is a combination of
both forced and resonant vibration. Forced vibration can be due to internally generated forces,
unbalances, external loads, ambient excitation. Resonant vibration occurs when one or more
of the resonances or natural modes of vibration of a machine or structure are excited[4].
2. Mathematical Model
Two stage four-gear trains with three rotational degrees of freedom are considered as
shown in figure 1. The tooth meshes are modelled as linear springs with varying stiffness [1].
The equivalent masses are m 1=I1 /r1 , m2=I2 /r2 , and m3= I3 /r3 . The equivalent stiffnesses
2 2 2

are k0=kL0 /r1 , k1=kL1, and k2= kL2 [1]. The stiffness of gear meshing pair basically depends
2 2

on three components, gear body, tooth and contact zone. There is a periodic variation in
 Proc. of the 5th International Conference on Advances in Mechanical Engineering (ICAME-2011), June 06-08, 2011
S.V. National Institute of Technology, Surat 395 007, Gujarat, India

meshing stiffness. Mathematical model for gear pair meshing is developed considering a
spring of varying stiffness between gears teeth contact as shown in figure 2 [2].

Figure 1 Two-stage four gear system [1] Figure 2 Model of meshing gear [2]
The system stability is governed by the free vibration equation
Mq + [K 0 + K v (t)]q = 0 (1)
The stiffness matrix is represented by a mean value K 0 and a variational part K v (t ) as
k g1 + k 0 k g1 0 k v1 k v1 0
K0 = k g1 k g1 + k g2 k g2 K v (t ) = k v1 k v1 + k v 2 k v2 (2)
0 k g2 k g2 0 k v2 k v2
Where k gi and k vi (t ) are the mean and time varying component of the mesh
stiffnesses [1].
k i (t) = k gi + k vi (t ) [1] (3)
The variational part k vi (t ) expressed in Fourier series as

k vi (t ) = 2k ai (a i s sinsi t + b i s cos si t ),
( ) ( )
i =1, 2 [1]
s=1
(4)
Where 2k ai is the peak to peak amplitude of stiffness k vi . The mesh frequencies

1 and 2 are related by 1 = R 2 , where R = Z 2 and Z2 and Z4 are the number of teeth
Z4
on gear 2 and 4. For spur gears, rectangular waves are often used to approximate the mesh
stiffness alternating between n and n+1 pair of teeth in contact [1].
2
sin[s(c i - 2pi )]sin(sc i ),
( )
ai s = (5)
s
2
cos[s(c i - 2pi )]sin(sc i ) .
( )
bi s = (6)
s
For s = 1, 2, 3n. without loss of generality, mesh phasing can be specified as p 1=0 and
p2=h. Here in this study, first four terms are used to approximate the variation in stiffness [1].
The Eigenvalue problem associated with motion equation and vibration modes are
normalised. A modal model is constructed using the orthogonality principle [3,4]. The
frequency response function (FRF) is calculated by solving the equation
() = ([K] - 2 [M])
-1
(7)
Where, is an excitation frequency[4].
3. Mathematical Simulation
After gear modelling MATLAB simulation is carried out to predict the natural
frequencies of a system. The parametric data are used for the computation.
 Proc. of the 5th International Conference on Advances in Mechanical Engineering (ICAME-2011), June 06-08, 2011
S.V. National Institute of Technology, Surat 395 007, Gujarat, India

Table 1 Parametric Data of Gear system

Sr. no Parameter Value
1 Equivalent masses m1= 2.403 kg, m2 = 5.642 kg, m3 = 2.963 kg
5
2 Average Mesh Stiffness Kg1= kg2 = 7.773x 10 N/m
5
3 Anchor Shaft Stiffness ko= 0.888x 10 N/m
4 Contact Ratio c1= c2= 1.55
5 Mesh Phasing p1= 0, p2 =h=0.5
5
6 Peak to Peak Amplitude ka1 = ka2 =3.25 x 10 N/m
7 Mesh Frequencies 1 = 1582.56 2 = 1230.8 rad/sec

ANSYS Modal analysis is carried out for a given speed reducer model.

Figure 3 ANSYS Mesh model Figure 4 Experimental Set up

4. Experimental Work
A gear box of Mild steel plate of 14 mm thickness is fabricated having outer
dimensions of 500 x 230 x200 mm. MS Shaft, two pair of pinion and gear with 42 and 54 teeth
respectively, ball bearing are assembled. 0.5HP DC motor is used to drive the system. OROS
make FFT Analyser is used to measure the vibration characteristics of gear system in running
conditions. FRF data are captured at some instants.
Table 2 Detail specification of pinion and gear
No Description Pinion Gear
1 No of teeth 42 54
2 Module 3 mm
3 Pitch diameter 126 mm 162 mm
0
4 Pressure angle 20
5 Addendum circle diameter 132 mm 168 mm
6 Deddendum circle diameter 118.5 mm 154.5 mm
7 Contact ratio 1.55 1.55
8 Shaft diameter 24 mm
9 Centre Distance 144 mm
10 Face Width 20 mm

5. Results & Discussion

MATLAB and ANSYS simulated results are compared to the experimental results.
Variation in natural frequencies are clearly shown. Second and third natural frequencies are
 Proc. of the 5th International Conference on Advances in Mechanical Engineering (ICAME-2011), June 06-08, 2011
S.V. National Institute of Technology, Surat 395 007, Gujarat, India

more affected by the variation in stiffness compare to first natural frequency. As the structure
have infinite degree of freedoms, there are infinite natural frequencies captured from
experiments. Results are compared for few of them only.

Table 3 variation in natural frequencies

Frequency Hz n1 n 2 n3
Maximum 13.94 106.89 148.53
Minimum 13.37 67.13 93.18
Average 13.67 81.92 124.08
%tage Variation 4.12 37.20 37.26

Table 4 Comparisons of results

Natural Frequencies Hz
No
MATLAB ANSYS Experimental

1 13.93 13.238 14.8

2 55.744 56.3

3 79.052 79.7

4 104.76 115.85 114.2

5 146.66 139.87 139

6 329.26 328

Due to continuous change in contact position of gear teeth during the actual operation,
there occurs change in load position, tooth bending and elastic deformation of contacting
teeth. Previous research suggested various parameters which affects the mesh stiffness.
Contact ratio and mesh frequencies are important from subject point of view[1,3,4].
From the plot of FRF it is seen that second and third natural frequencies are more
affected by the variation in stiffness. Rotational speed of the gearbox should be tuned properly
such that the natural frequencies are sufficiently away from the excitation frequencies to avoid
resonance. Present numerical analysis suggests that geometric parameters of gear system
play an important role in dynamic performance. Mode shapes corresponding to natural
frequencies help to determine the critical area of vibration and help the designers to predict
the early fault detections and remedies.
Figure 6 shows that second and third natural frequencies are relatively changing more
rapidly as compared to first natural frequency. Second and third natural frequencies vary
about 35 to 40%. Periodic variation imparts excessive vibration due to change in load and
contact of tooth area, which is generally ignored during static design, but in actual practice
there, always resides significant contact variation during operation of gears. Gears, which are
prone to fatigue loading, can get detrimentally affected in wear and tear of gear tooth-profile
lead to loss of accuracy. Dynamic instability causes separation of tooth contact, which
generates impulse and consequently rattles noise.
 Proc. of the 5th International Conference on Advances in Mechanical Engineering (ICAME-2011), June 06-08, 2011
S.V. National Institute of Technology, Surat 395 007, Gujarat, India

-2
10
plot natural frequencies vs time

1000
-4
10 900
response FRF

800

natural frequencies Rad/sec

700
-6
10 600

500

400
-8 300
10
200

100

-10 0
10 0 1 2 3 4 0 1 2 3 4 5 6
10 10 10 Rad/sec
Frequency 10 10 time sec
n

Figure 5 Plot of FRF vs. Frequency figure 6 Plot of Natural frequencies Vs. time

plot of varying mesh stiffness vs time for gear

pair 2

500000
varying mesh stiffness N/m

400000
300000
200000
100000
0
-100000 0 1 2 3 4 5 6
-200000
-300000
-400000
-500000
time sec

Figure 7 Plot of Natural Frequencies vs. acceleration figure 8 plot of varying mesh stiffness vs. time
for gear pair 2
6. Conclusion
Modelling of a three stage gearbox is done. Prediction and validation of natural
frequencies of an undamped gearbox is presented by considering the effect of time varying
mesh stiffness by MATLAB, ANSYS and experiments results. Due to variation in mesh
stiffness of the mating teeth, there occurs variation in natural frequencies. Study of effect of
other geometrical and operating parameters will help to understand the complex behaviour of
gear system.

7. References

[1] Jian Lin, Robert G Parker, Mesh Stiffness Variation Instabilities in Two-Stage Gear
Systems, ASME Journal of Vibration and Acoustics JAN. 2002, Vol. 124, pp 68-76
[2] H-H. Lin, R.L. Huston, J. J. Coy, On Dynamic Loads in Parallel Shaft Transmissions:
Part I- Modelling and Analysis, ASME Journal of Mechanisms, Transmissions, and
Automation in Design JUNE 1988, Vol. 110, pp 221-225.
[3] H-H. Lin, R.L. Huston, J. J. Coy, On Dynamic Loads in Parallel Shaft Transmissions:
Part II- Parameter Study, ASME Journal of Mechanisms, Transmissions, and
Automation in Design JUNE 1988, Vol. 110, pp 226-229.
[4] Jimin He and Zhi-Fang Fu Modal Analysis, Butterworth-Heinemann Linacre House,
Jordan Hill, Oxford OX2 8DP 2001.