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V. Zeman
M. Byrtus
University of West Bohemia in Pilsen University of West Bohemia in Pilsen
Pilsen, Czech Republic
Pilsen, Czech Republic
Abstract The contribution presents the original
method of the mathematical modelling of gear drive nonlinear vibrations using modal synthesis method with DOF
number reduction. The model respects nonlinearities
caused by gear mesh interruption and by contact forces acting between journals of the rolling-element bearings and
the outer housing. As a result of nonlinear couplings, gearbox vibrations in case of small static load and in resonances
are accompanied by impact motions, bifurcation of solution
and chaotic motions. The presented method is applied to
the real car gearbox.
Keywords: gearbox, nonlinear vibration, nonlinear couplings,
modal synthesis method
I. Introduction
The gear drive and gearboxes vibrations are commonly
investigated with the assumption of linearized coupling
forces [1], [2] or for an isolated gear pair with nonlinear
meshing coupling [3]. These simplifying assumptions are
acceptable for the system with gears only if dynamic meshing deformations are smaller than their static deformations
and in cases when the housing is relatively rigid and the
interaction between single pairs of gears is neglectable.
B2
s=1
G1
G2
G5
G3
4
s=2
B4
B3
G6
1
2
s=3
kL
B5
IL
zemanv@kme.zcu.cz
byrtus@kme.zcu.cz
Generally, the subsystems rotating with angular velocity s are described in local generalized coordinates qs (t)
with system of ns ordinary differential equations in matrix
form [6]
G4
3
A. Modelling of subsystems
s=4
B1
B6
kR
IR
(1)
y
$ i, j
e i, j
$i
H i, j
ax
F i, j
ax
F i, j
&i
ri
vi
wi
"i
Fi
Si
e i, ax
!i
ui
!i
Si
"i
B. Bearing model
The bearing model, used in our approach to gearbox
modelling, respects real number of rolling elements uniform distributed between the inner and outer race (see figure 2). Let us suppose that the rolling-element j of the bearing i touches the outer race at the contact point Hi,j . The
force Fi,j trasmitted at this point depends nonlinearly on
the rolling-element deflection i,j according to the Hertzs
contact theory in this way
Fi,j
ax
Fi,j
"n
i,j
=
H(i,j ),
C
! ax "n
i,j
=
H(ax
i,j ).
C
(2)
The designation ax belongs to axial deflections of rollingelements and corresponding axial forces that moreover
arise in the radi-axial rolling bearings. The deflections originate from the deformation of the rolling elements and the
races at the contact points. Parameters n and C depend on
rolling-elements geometry, elastic modulus and Poissions
ratio of the bearing components, as mentioned in [7]. Heaviside function H corrects the contact forces when the deflections are negative which means that the rolling elements
are unloaded.
The calculation of the deflections i,j and ax
i,j supposing the rigid inner and flexible outer race, is in detail described in [5].
Then the vector fsB in equation (1) (model of rotating
parts) can be expressed in following form
fsB =
#
i,j
ax
(ti,j Fi,j + tax
i,j Fi,j ), s = 1, . . . , S 1, (3)
(4)
i,j
&i
vi
z
H i, j
n=
S
#
ns
(5)
s=1
ax
(ci,j Fi,j + cax
(6)
fB = . =
i,j Fi,j ).
..
fSB
i,j
where KB and BB are global stiffness and damping bearing matrices. Their structure depends on the number of
rolling elements and on the nodal points to which they are
fixed on the shafts (for details see [4]). The bearing damping matrix is supposed to be proportional to the stiffness
matrix
BB = B KB
(9)
and functions fi,j have form
,!
"n
i,j
ki,j i,j H(i,j )
fi,j (i,j ) =
C
ki,j i,j H(i,j ).
(10)
ax
In the same way can be expressed the function fi,j
(ax
i,j ).
The parameters ki,j represent linearized rolling-elements
stiffness that is calculated in dependence on an external
static torsional loading of driving and driven shafts as was
shown in [5].
C. Gearing model
The force effect of the spur helical gear coupling Gz (see
figure 1) in (1) is expressed by vector
#
fsG =
(11)
z,i Fz (t, dz , dz ),
z
(12)
qi (t) = [. . . ui vi wi i i i . . . ]T and qj (t) having similar form describe displacements of nodal points i and j.
The function z (t), defining kinematic transmission error
of gearing z, can be expressed by Fourier series
z (t) =
K
#
S
(C
z,k cos kz t + z,k sin kz t),
+ fG (t),
f G = ... =
cz Fz (t, q, q)
(16)
f G z=1
S1
0
where fG (t) is vector of internal kinematic excitation generated in gear meshing that can be expressed in form
fG (t) =
Z .
#
z=1
/
z (t) cz .
kz z (t) + bz
rj
uj
wj
f G = KG q BG q +
y
i
A
vi
Gearing deformation
dz (t) =
(19)
It is advantageous to assemble condensed mathematical model of the system with reduced degrees of freedom
(DOF) number, because, in particular, the housing subsystem could have too large DOF number and this can hinder
from consecutive performing of various dynamical analyses
and optimization. The modal transformations
ri
T
z,i
qi (t)
cz fz (t, q) + fG (t),
z=1
ui
wi
Z
#
driving gear
(18)
vj
(17)
driven gear
(15)
k=1
qs (t) = m Vs xs (t),
(14)
s = 1, 2, . . . , S,
(20)
m=
S
#
ms .
(21)
s=1
The model (1) can be then rewritten using terms (8) and
(19) in the global condensed form
/
.
(t) + B + 0 G + VT (BB + BG ) V x(t)+
x
/
.
+ + VT (KB + KG ) V x(t) =
.##
(22)
ax
= VT
(ci,j fi,j (q) + cax
i,j fi,j (q))+
+
Z
#
z=1
/
cz fz (t, q) + fG (t) + fE (t) ,
x(0)
= 0
(24)
S2,1
S2,1
, S2,3 =
,
2
3
(25)
S6,1
S6,1
S
, 6,3 =
,
=
2
3
C
C
C
C
= C
2,2 = 2,3 = 6,1 = 6,2 = 6,3 = 0.
S2,2 =
S6,2
C
2,1
tT
(26)
00
6
15
10
0
500
above mentioned harmonic components with the fundamental frequency equal to the meshing frequency. There
are many peaks corresponding to resonance states of the
gearbox on the boundary between constant and interrupted
gear mesh. The gear box shows greater displacements and
thence greater gearing deformations and greater tendency
towards gear mesh interruption in all resonance states.
20
6e-006
15
3e-006
10
500
of the model. The time response of such systems is accompanied by bifurcation of solution in dependence on chosen
operational parameters. Vibro-impact systems are characterized by period doubling scenario, when the period number of the time response increases unexpectedly twice for
a certain values of operational parameters. This scenario
could repeat till the motion becomes chaotic. Moreover,
the time response of nonlinear model is influenced by impacts in gear meshings with one freely rotating gear. These
motions are neglected in the linearized model used before.
All results introduced here are gained for the condensation level of the car-gearbox and for kinematic transmission
errors mentioned in the chapter before.
minima and maxima of gearing deformation d2 [m]
006
6e-
3e
-
20
!6
x 10
6
4
2
0
!2
!4
!6
!8
2000
2500
3000
3500
Fig. 6. Bifurcation diagram for minima (black dots) and maxima (grey
dots) of gearing deformation of the second gear mesh transmitting the
power corresponding to the static torque of 5 [Nm], see figure 4.
Figure 6 shows the bifurcation diagram of gearing deformation of gearing z = 2 for a chosen revolution range
of the gearbox, which is inscribed with the bold black line
in figure 4. The corresponding statical external torque has
than value of M = 5 Nm. In the bifurcation diagram a line
designating the zero gearing deformation is plotted. Each
dot plotted under this line corresponds to gear mesh interruption during one period of motion. Grey dots agree with
local maxima of gearing deformation and the black ones
agree with local minima, respectively. In the chosen operational area exist periodical solutions which follow the period doubling scenario. This nonlinear phenomenon mostly
accompanies the crossing of the area of constant gear mesh,
as [5] shows. Since the time course of the gearing deformation has a quasi-periodical structure, it is very difficult to
detect points of period doubling in the diagram 6.
Comparing figures 6 and 4, the point of loss of the constant gear mesh agrees and it happens at 2500 rpm. Increasing revolutions the motion overcomes according the nonlinear model to chaotic motion in the range of 2900-3000
rpm and 3250-3500 rpm. The contact loss endures then for
x 10
x 10
-6
3
3
1.5
1
0.5
(a)
0.005 0.01
(b)
-0.02
-6
x 10
-0.01
0.01
0.02
-6
5
0
4
3
-2
2
1
0
!6
-6
2.5
dz [m]
-4
(c)
-6
-0.02
(d)
0.02
-0.02
0.02
dz [ms1 ]
0
!1
!2
!3
!4
!5
!6
!7
2000
2500
3000
3500
Fig. 7. Bifurcation diagram for minima (black dots) and maxima (grey
dots) of gearing deformation of the fifth gear mesh with freely rotating
driven gear corresponding to the static torque of 5 [Nm].
By increasing the level of external torque M and by decreasing the revolutions per minute of the driving shaft the
motion becomes more stable and the areas of chaotic motion disappear, as figures 4 and 6 shows. Moreover, the
number of impacts per one period of motion decrease. Figure 8 shows the evolution of phase trajectories of the second
and fifth gear meshes for different values of revolutions of
the driving shaft. The picture (a) shows a quasi-periodic solution of gearing deformation d2 corresponding to the motion with no impacts in gearing. Pictures (b) and (c) display
a quasi-periodic solution of the gear mesh G2 deformation
with contact loss in gearing. The case (d) corresponds to a
chaotic solution of the gear mesh deformation of the meshing G5 , which includes a freely rotating gear transmitting
no power.
IV. Conclusion
The paper describes the methodology of the large coupled rotating systems modelling and the analysis of their
nonlinear vibrations. The models of these systems suppose
a flexible stator and nonlinear gear couplings between rotor subsystems and nonlinear rolling-element bearings. The
whole system model is created by means of the modal synthesis method which allows to reduce number of degrees of
freedom of the mathematical model. The methodology is
applied to the real gearbox. Nonlinear vibrations excited
by kinematic transmission error accompanied by nonlinear
phenomena like bifurcation, periodic and quasi-periodic solutions and chaos are investigated. These regions of motions and changes among the regions are very interesting
from the theoretical and practical point of view.
This work was supported by the research project MSM
4977751303 of the Ministry of Education, Youth and Sports
of the Czech Republic.
References
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[2]
[3]
[4]
[5]
[6]
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