Professional Documents
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Song He
Acoustics and Dynamics Laboratory,
Solutions to Spur Gear Dynamics
Department of Mechanical Engineering,
The Ohio State University,
Given Periodic Mesh Stiffness
Columbus, OH 43210
e-mail: he.81@osu.edu and Sliding Friction Functions
Todd Rook Gear dynamic models with time-varying mesh stiffness, viscous mesh damping, and slid-
Goodrich Aerospace,
ing friction forces and moments lead to complex periodic differential equations. For
101 Waco Street,
example, the multiplicative effect generates higher mesh harmonics. In prior studies,
Troy, OH 45373
time-domain integration and fast Fourier transform analysis have been utilized, but these
e-mail: todd.rook@goodrich.com
methods are computationally sensitive. Therefore, semianalytical single- and multiterm
harmonic balance methods are developed for an efficient construction of the frequency
Rajendra Singh responses. First, an analytical single-degree-of-freedom, linear time-varying system
Fellow ASME,
model is developed for a spur gear pair in terms of the dynamic transmission error.
Acoustics and Dynamics Laboratory,
Harmonic solutions are then derived and validated by comparing with numerical inte-
Department of Mechanical Engineering,
gration results. Next, harmonic solutions are extended to a six-degree-of-freedom system
The Ohio State University,
model for the prediction of (normal) mesh loads, friction forces, and pinion/gear dis-
Columbus, OH 43210
placements (in both line-of-action and off-line-of-action directions). Semianalytical pre-
e-mail: singh.3@osu.edu
dictions compare well with numerical simulations under nonresonant conditions and
provide insights into the interaction between sliding friction and mesh stiffness.
关DOI: 10.1115/1.2988478兴
Journal of Mechanical Design Copyright © 2008 by ASME DECEMBER 2008, Vol. 130 / 122601-1
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Fig. 1 „a… Periodic mesh stiffness functions of the spur gear
pair example „with tip relief… given nominal pinion torque T̄p
= 550 lb in. Key: blue dashed line, k0„t…; red solid line, k1„t…. „b…
Periodic frictional functions. Key: blue dashed line, f0„t…; green
dashed-dotted line, f1„t…; red solid line, f2„t….
Fig. 2 „a… Snap shot of the contact pattern „at t = 0… for the
pinion and gear are rigid disks. 共ii兲 Vibratory motions are small in sample spur gear pair. „b… Normal „mesh… and friction forces of
comparison to the nominal motion; this would lead to a LTV the analytical spur gear system model.
model. Only nonresonant conditions are considered since signifi-
cant dynamic motions at resonance may not only change the con-
tact pattern 共such as the effective center distance兲 but also cause
teeth separation, which would introduce nonlinear interactions and X pi共t兲 = LXA + 共S − i兲 + mod共⍀̄ prbpt,兲, i = 0, . . . ,S = floor共兲
further complicate the formulation. 共iii兲 The Coulomb friction is 共1e兲
assumed with a constant although the sign is reversed at the
pitch point. Xgi共t兲 = LYC + i − mod共⍀̄grbgt,兲, i = 0, . . . ,S = floor共兲
The governing SDOF equation in terms of DTE ␦共t兲 = rbp p共t兲
− rbgg共t兲 is given below, where subscripts p and g correspond to 共1f兲
the pinion and gear, respectively; is the vibratory component of S S
the rotation; T̄ and ⍀̄ are the nominal torque and rotation speed;
is the base pitch; and J is the moment of inertia. Note that Je is
T共t兲 = Jb 兺
i=0
关ci共t兲˙ 共t兲 + ki共t兲共t兲兴 + 兺 sgn关mod共⍀̄ r
i=0
p bpt,兲
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LXA = l sin ␣wt − 冑r2ag − r2bg 共2a兲 Each periodic function, ki共兲, ci共兲, f i共兲, or ␦共兲, now has a pe-
riod of T = 1. Figure 1共b兲 shows typical f 0共兲, f 1共兲, and f 2共兲
LYC = 冑r2ag − r2bg + 共2b兲 functions, which describe the periodic moment arm and sliding
friction excitations for the sample case 关10兴.
ul sin ␣wt
LAP = 冑r2ag − r2bg − 共2c兲 3.1 Direct Application of Multiterm Harmonic Balance.
u+1 Define the Fourier series expansions of the periodic ki共兲 and ci共兲
Observe that Eqs. 共1a兲–共1g兲 significantly differs from the clas- in Eqs. 共4a兲–共4e兲 up to N mesh harmonics as follows, where the
sical Hill’s equation 关13兴 in several ways. First, the periodic ki共t兲 angular frequency n = 2n 共in rad/s兲 and n is the mesh order:
is not confined to a rectangular wave assumed by Vaishya and N N
Singh 关5–7兴 or a simple sinusoid as in Mathieu’s equation 关1兴.
Instead, Eqs. 共1a兲–共1g兲 should describe realistic, yet continuous, ki共兲 = Aki0 + 兺
n=1
Akin cos共n兲 + 兺B
n=1
kin sin共n兲 共5a兲
profiles of Fig. 1共a兲 resulting from a detailed FE/CM analysis
关16兴. Hence, multiple harmonics of ki共t兲 should be considered.
冕
1
Second, the periodic viscous ci共t兲 term should dissipate vibratory
Aki0 = ki共兲d 共5b兲
energy due to the sliding friction besides its kinematic effect.
0
␦i共t兲ci共t兲 and 兺i=1
S ˙
Third, the 兺i=1 S
␦i共t兲ki共t兲 terms of Eqs. 共1a兲–共1g兲
冕
incorporate combined 共but phase correlated兲 contributions from 1
all 共yet changing兲 tooth pairs in contact. Consequently, the relative Akin = 2 kin cos共n兲d 共5c兲
phase between neighboring tooth pairs should play an important 0
role in the resulting response ␦共t兲. Fourth, multiplicative effects
冕
between ki共t兲, ci共t兲, Xi共t兲, and ␦共t兲 should result in higher mesh 1
harmonics, which poses difficulty in constructing closed-form so- Bkin = 2 kin sin共n兲d 共5d兲
lutions. Lastly, the coupling between T共t兲 and 共t兲 in Eq. 共1g兲 0
indicates that the frictional forces and moments reside on both
sides of Eq. 共1a兲 as either periodically varying parameters or ex- N N
ternal excitations, thus posing further mathematical complications. ci共兲 = 2冑ki共兲Ie = Ac i0
+ 兺A cin cos共n兲 + 兺B cin sin共n兲
n=1 n=1
共6a兲
3 Semianalytical Solutions to the SDOF Spur Gear
Dynamic Formulation
冕
1
Consider the sample case with only the mean load Te, i.e., Adi0 = ci共兲d 共6b兲
T共t兲 = 0 or 共t兲 = 0. Equations 共1a兲–共1g兲 can be rewritten over one 0
冕
1
with two mesh tooth pairs, where me and Fe are the effective mass
and force; E1, E2, and E3 are gear constants, Acin = 2 cin cos共n兲d 共6c兲
0
me␦¨ 共t兲 + 关c0共t兲␦˙ 共t兲 + k0共t兲␦共t兲兴关1 + E1 + E3t兴 + 关c1共t兲␦˙ 共t兲
冋 冉 冊册 冕
1
LAP cin sin共n兲d 共6d兲
+ k1共t兲␦共t兲兴 1 + 共E2 + E3t兲sgn t − = Fe 共3a兲 Bcin = 2
⍀̄ prbp 0
兺
1 1
f 0共 兲 = − sin共n兲 共7a兲
E3 = ⍀̄ prbp共Jgrbp − J prbg兲/Jb 共3d兲 2 n=1 n
me = Je/Jb 共3e兲 N
4 sin共n P兲
Fe = Te/Jb 共3f兲
f 1共 兲 = 1 − 2 P − 兺
n=1 n
cos共n兲
再兺
c
冎
n=1
f 1共兲 = sgn关mod共,1兲 − P兴 = sgn关f 0共兲 − P兴 共4c兲
P = LAP/ 共4e兲 Finally, assume that the periodic dynamic response ␦共兲 is of
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the following form:
N N
␦ 共 兲 = A ␦0 + 兺 A␦
n=1
n cos共n兲 + 兺 B␦
n=1
n sin共n兲 共8兲
冤 冥冤冥
A ␦0 Fe
A ␦1 0
B ␦1 0
= h兴
关K = 共9兲
... ...
A ␦N 0
B ␦N 0
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¯ 兲共1 + E + E
K共兲 = k0共 ¯ ¯ ¯ ¯
1 4 兲 + k1共兲关1 + 共E2 + E4兲sgn共/LAP
− 1兲兴 共14c兲
For the MHBM, the discrete Fourier transform 共DFT兲 is applied to
transform from the time domain to the frequency domain, and a
discretized Fourier expansion matrix F= transforms the frequency
domain back to the time domain,
冤 冥
1 sin共1兲 cos共1兲 . . . sin共N1兲 cos共N1兲
1 sin共2兲 cos共2兲 . . . sin共N2兲 cos共N2兲
F= =
] ] ] ] ]
1 sin共 M 兲 cos共 M 兲 . . . sin共N M 兲 cos共N M 兲
共15a兲
冦 冧
␦ 共 1兲
␦ 共 2兲
␦គ ⬅ = F= ⌬គ 共15b兲
]
␦共 M 兲
冦 冧
␦ˆ 共1兲
Fig. 4 Semianalytical versus numerical solutions for the
␦ˆ 共2兲 SDOF model as a function of pinion speed with = 0.04. „a…
␦គ̂ ⬅ =⌬
= F= D គ 共15c兲 Mesh order n = 1, „b… n = 2, „c… n = 3, and „d… n = 4. Key: red ⴛ,
] numerical simulations; blue solid line, semianalytical solutions
␦ˆ 共M 兲 using five-term HBM.
冦冧
␦ˆ 共1兲
observed in the numerical simulations. The semianalytical solu-
tions are efficiently used in Fig. 4 for parametric studies of ␦共兲 at
␦ˆគ ⬅ ␦ˆ 共2兲 = 2⌬គ
= F= D 共15d兲
the gear mesh harmonics over a range of ⍀̄ p, and these calcula-
]
tions are indeed achieved with reduced computational cost.
␦ˆ 共M 兲
Here, i = i2 / M and M 艌 2N + 1, ⌬ គ is a vector of 2N + 1 Fourier 4 Semianalytical Solutions to 6DOF Spur Gear Dy-
coefficients, and the Fourier differentiation matrix D= is given as namic Formulation
冤 冥
0 0 0 ... 0 0 A careful examination of the 6DOF model reported in Ref. 关10兴
0 0 − 1 ... 0 0 reveals that the dynamic bearing displacement y共兲 in the OLOA
direction depends on the LOA dynamics since the friction force
0 1 0 ... 0 0 k共兲␦共兲 acts in the OLOA direction. Conversely, the dynamic
= =
D 共15e兲
] ] ] 0 0 bearing displacement x共兲 in the LOA direction is not influenced
0 0 0 ... 0 − N by 共i.e., is decoupled from兲 the OLOA motion y共兲. This is be-
cause of the following reasons: First, no off-diagonal term exists
0 0 0 ... N 0
in the effective shaft-bearing stiffness matrix that couples the
冤 冥
LOA and OLOA dynamics 关8兴. Second, the friction force de-
0 0 0 ... 0 0
scribed by the Coulomb model is independent of y共兲. Third, re-
0 −1 0 ... 0 0 call our assumption that the dynamic responses 共such as y共兲兲
0 0 − 1 ... 0 0 have no influence on the kinematics 共such as the center distance兲.
=2=
D 共15f兲 Such “one-way coupling” between LOA and OLOA dynamics im-
] ] ] 0 0
plies that we can reduce the 6DOF model into a simpler 3DOF
0 0 0 . . . − N2 0 model 关21兴 in terms of x p共兲, xg共兲, and ␦共兲. Dynamic responses
0 0 0 ... 0 − N2 of the 3DOF model could further be used to determine the friction
Applying the DFT to the equation of motion yields the following forces that excite the OLOA dynamics.
MHBM equations where F= + is the Moore–Penrose or pseudoin- For the 3DOF system, when the composite DTE ␦共兲
verse of the DFT matrix, = rbp p共兲 − rbgg共兲 + x p共兲 − xg共兲 can be approximated by the
semianalytical solution ␦共兲 = rbp p共兲 − rbgg共兲 of the SDOF
关⍀̃2meD
= 2 + ⍀̃F= +C = F= 兴⌬គ = F= +Fគ e
= + F= +K
= F= D 共16a兲 model, a similar one-way coupling is created where ␦共兲 is decou-
pled from x p共兲 and xg共兲, while x p共兲 and xg共兲 are excited by
= ⬅ diag共兵K共1兲
K K共2兲 ¯ K共 M 兲其兲 共16b兲 ␦共兲 in terms of the normal loads. This suggests that when the
excitation 共mesh兲 frequencies do not excite any coupled
= ⬅ diag共兵C共1兲
C C共2兲 ¯ C共 M 兲其兲 共16c兲 transverse-torsional modes in the LOA direction, the harmonic
solutions of the SDOF system could be extended to predict trans-
Fគ e = 关Fe 0 ¯ 0 0兴T 共16d兲 lational responses in both LOA and OLOA directions by utilizing
Figure 3 shows that the five-term HBM solutions compare well the one-way coupling effects. Note that the semianalytical method
with numerical simulations. Likewise, an increase in N captures analyzes the 6DOF system 关10兴 as a 5DOF model as it calculates
higher frequency components around the tenth mesh harmonic, as the ␦共t兲 rather than absolute angular displacements p共t兲 or p共t兲.
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In order to quantify the nonresonant condition under which the sample case: mass of pinion 共gear兲 m p = mg = M; moment of inertia
one-way coupling exists in the LOA direction, we use a 6DOF J p = Jg = J; basic radius rbp = rbg = R; the equivalent mass me
linear time-invariant spur gear model of Fig. 5共a兲 and focus on its = J / 共2R2兲; time-averaged mesh stiffness km 共T p = 550 lb in.兲; shaft-
subset of a unity gear pair 共3DOF model兲 to study the natural bearing stiffness KBp = KBg = KB. The natural frequencies of the
frequency distribution. We define the following parameters for the 3DOF system are found as follows 关21兴:
Fig. 5 „a… 6DOF spur gear pair model and its subset of unity
gear pair „3DOF model… used to study the natural frequency Fig. 6 Semianalytical versus numerical solutions for the 6DOF
distribution. „b… Natural frequencies ΩN as a function of the model as a function of Ω̄p with = 0.04. „a… Mesh order n = 1, „b…
stiffness ratio KB / km. Key: black solid line, ΩSN of SDOF sys- n = 2, „c… n = 3, and „d… n = 4. Key: blue solid line, predictions
tem „torsional only, in terms of DTE…; blue dashed line, ΩN1 of using five-term HBM; green 䊊, numerical simulations †4‡ with
3DOF system; green dotted line, ΩN2 of 3DOF system; red nominal KB „KB / km = 0.37…; red ⴛ, numerical simulations with
dashed-dotted line, ΩN3 of 3DOF system. stiff KB „KB / km = 100….
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for interactions between ki共兲 and ␦共兲 as well as between ci共兲
and ␦˙ 共兲, Fourier series is expanded to find the N 共兲 terms up to i
2N mesh harmonics,
2N
2N
+ 兺B
n=1
Nin sin共n兲 共18兲
共19a兲
3N Fig. 7 Semianalytical versus numerical solutions of the LOA
F f1共兲 = N1共兲f 1共兲 = AF10 + 兺A
n=1
F1n cos共n兲 displacement xp for the 6DOF model as a function of Ω̄p with
KB / km = 100, = 0.04. „a… Mesh order n = 1, „b… n = 2, „c… n = 3, and
3N
„d… n = 4. Key: red ⴛ, numerical simulations; blue solid line, pre-
dictions using five-term HBM.
+ 兺B
n=1
F1n sin共n兲 共19b兲
关10兴, where K pBx and pBx are the shaft-bearing stiffness and 2N
兺M
damping terms:
+ ␣ py共n兲兴 + py 共n兲BF0n sin关n + ␣ py共n兲兴
Xp t2c n=1
共兲 = 共20a兲
Np 共− 2m p + K pBxt2c 兲 + j2tc pBx冑K pBxm p 3N
M px共n兲 =
t2c
冑共− 2nmp + KpBxt2c 兲2 + 42nt2c 2pBxKpBxmp 共20b兲 + 兺M
n=1
py 共n兲BF1n sin关n + ␣ py共n兲兴 共23兲
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Fig. 8 Semianalytical versus numerical solutions of the OLOA Fig. 10 Semianalytical versus numerical solutions of the
displacement yp for the 6DOF model as function of Ω̄p with OLOA displacement yp for the 6DOF model as a function of Ω̄p
KB / km = 100, = 0.04. „a… Mesh order n = 1, „b… n = 2, „c… n = 3, and with KB / km = 0.37, = 0.04. „a… Mesh order n = 1, „b… n = 2, „c… n
„d… n = 4. Key: red ⴛ, numerical simulations; blue solid line, pre- = 3, and „d… n = 4. Key: green 䊊, numerical simulations; blue
dictions using five-term HBM. solid line, predictions using five-term HBM.
the perfect involute profile case 共without any tip relief兲 as a func- 5 Conclusion
tion of the mean torque T̄ p. Observe that for the perfect involute An application of the harmonic balance method to the gear
profile, the y p / x p ratios remain almost constant over the entire dynamic models with multiple periodic coefficients leads to an
torque range, while applying tip relief significantly alters the efficient algorithm to evaluate the effect of sliding friction on spur
y p / x p ratios. A peak ranging from 0.8 up to 15 is observed for the gear dynamics 共as compared with the numerical integration
long tip relief case around the “optimal” load of 550 lb in., imply- method 关10兴兲. Multiterm harmonic balance solutions based on the
ing that an amplification due to the sliding friction takes place. SDOF linear time-varying model are successfully extended to a
This can be explained by the fact that the application of tip relief 6DOF system model for the predictions of 共normal兲 mesh loads,
not only minimizes x p at the design load but also amplifies the friction forces, and bearing displacements in the LOA and OLOA
harmonic of y p due to an out-of-phase relationship between the directions. A simplified 3DOF linear time-invariant model is used
dynamic normal load N共兲 and dynamic friction forces F f 共兲 关10兴.
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to explain the nonresonant operating conditions under which the Parametric Effects in Gear Dynamics,” J. Sound Vib., 248共4兲, pp. 671–694.
关7兴 Vaishya, M., and Singh, R., 2003, “Strategies for Modeling Friction in Gear
proposed algorithm is applicable. Semianalytical solutions also Dynamics,” ASME J. Mech. Des., 125, pp. 383–393.
provide new insights into the multiplicative interactions between 关8兴 He, S., Gunda, R., and Singh, R., 2007, “Inclusion of Sliding Friction in
time-varying mesh stiffness 共say, with contributions from tip re- Contact Dynamics Model for Helical Gears,” ASME J. Mech. Des., 129, pp.
lief兲 and sliding friction 共including friction force excitation and 48–57.
关9兴 He, S., and Singh, R., 2008, “Dynamic Transmission Error Prediction of He-
varying torque兲. Such dynamic interactions explain the higher har- lical Gear Pair Under Sliding Friction Using Floquet Theory,” ASME J. Mech.
monic components and the phase relationship between sliding Des., 130共5兲, 052603.
friction and mesh stiffness function. These are the main contribu- 关10兴 He, S., Gunda, R., and Singh, R., 2007, “Effect of Sliding Friction on the
tions of our paper. The methods of this article could be extended Dynamics of Spur Gear Pair With Realistic Time-Varying Stiffness,” J. Sound
Vib., 301, pp. 927–949.
to multimesh spur gear dynamics. 关11兴 He, S., and Singh, R., 2007, “Dynamic Interactions Between Sliding Friction
and Tip Relief in Spur Gears,” DETC 2007-34077, Tenth International Power
Acknowledgment Transmission and Gearing Conference, Las Vegas, Sept. 4–7.
关12兴 Velex, P., and Ajmi, M., 2007, “Dynamic Tooth Loads and Quasi-Static Trans-
This article is based on a three-year study that was supported by mission Errors in Helical Gears—Approximate Dynamic Factor Formulae,”
the U.S. Army Research Office 关22兴. We acknowledge the Gradu- Mech. Mach. Theory, 42共11兲, pp. 1512–1526.
ate School of The Ohio State University for awarding the Presi- 关13兴 Richards, J. A., 1983, Analysis of Periodically Time-Varying Systems,
Springer, New York.
dential Fellowship to the first author. 关14兴 Jordan, D. W., and Smith, P., 2004, Nonlinear Ordinary Differential Equations,
3rd ed., Oxford University Press, New York.
关15兴 Thomsen, J. J., 2003, Vibrations and Stability, 2nd ed., Springer, New York.
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