Intermittent gear rattle due to interactions between forcing and manufacturing errors

The interaction between eccentricity and an external forcing fluctuation in gear rattle response is investigated experimentally. The experimental rig consists of a 1:1 ratio steel spur gear pair, the input gear being controlled in displacement and the output gear being under no load. Gear transmission errors recorded using high accuracy encoders are presented. Large variations in backlash oscillation amplitude are observed as the relative phase of the input forcing and the sinusoidal static transmission error due to eccentricity is varied. A simplified mathematical model incorporating eccentricity is developed. It is compared with experimental findings for three different gear eccentricity alignments by way of plots relating backlash oscillation amplitude to forcing amplitude and phase relative to eccentricity sinusoid. It is shown that eccentricity does not fully account for the experimentally observed large variations in amplitude. Through analysis of the experimental data, it is suggested that further tooth profiling errors may explain the discrepancies.

[1]  Giorgio Bonori,et al.  Non-smooth dynamics of spur gears with manufacturing errors , 2007 .

[2]  Joanna F. Mason,et al.  Mathematical Models of Gear Rattle in Roots Blower Vacuum Pumps , 2006 .

[3]  J. Der Hagopian,et al.  Vehicle driveline dynamic behaviour experimentation and simulation , 1998 .

[4]  Homer Rahnejat,et al.  Gear teeth impacts in hydrodynamic conjunctions promoting idle gear rattle , 2007 .

[5]  S. Theodossiades,et al.  Lightly loaded lubricated impacts: Idle gear rattle , 2007 .

[6]  Friedrich Pfeiffer,et al.  Rattling models from deterministic to stochastic processes , 1990 .

[7]  C. C. Wang,et al.  Rotational Vibration With Backlash—Part 2 , 1981 .

[8]  Just L. Herder,et al.  Design of a Statically Balanced Tensegrity Mechanism , 2006 .

[9]  R Manoj,et al.  Gear rattle modelling and analysis for automotive manual transmissions , 2001 .

[10]  R. E. Wilson,et al.  Coexisting solutions and bifurcations in mechanical oscillators with backlash , 2007 .

[11]  S Du,et al.  Modelling of spur gear mesh stiffness and static transmission error , 1998 .

[12]  H. N. Özgüven,et al.  Dynamic analysis of high speed gears by using loaded static transmission error , 1988 .

[13]  Rajendra Singh,et al.  Strategies for Modeling Friction in Gear Dynamics , 2003 .

[14]  Charles E. Wilson,et al.  Kinematics and dynamics of machinery , 1983 .

[15]  Donald R. Houser,et al.  Mathematical models used in gear dynamics—A review , 1988 .

[16]  Donald R. Houser,et al.  Estimation of Reference Misalignment of a Spur Gear and its Application to Profile and Lead Measurement , 2002 .

[17]  D. A. Crolla,et al.  Dynamics and control of gearshifts on twin-clutch transmissions , 2005 .

[18]  Rajendra Singh,et al.  Analysis of automotive neutral grear rattle , 1989 .

[20]  C. C. Wang,et al.  Rotational Vibration With Backlash: Part 1 , 1978 .

[21]  P. Velex,et al.  A MATHEMATICAL MODEL FOR ANALYZING THE INFLUENCE OF SHAPE DEVIATIONS AND MOUNTING ERRORS ON GEAR DYNAMIC BEHAVIOUR , 1996 .

[22]  Anand Parey,et al.  Spur gear dynamic models including defects: A review , 2003 .

[23]  William D. Mark.  Contributions to the vibratory excitation of gear systems from periodic undulations on tooth running surfaces , 1992 .

[24]  Rajendra Singh,et al.  Non-linear dynamics of a spur gear pair , 1990 .

[25]  James R. Ottewill,et al.  An Experimental Analysis of the Dynamics of Lightly Damped Subcritically Excited Gear Pairs , 2007 .

[26]  Friedrich Pfeiffer,et al.  Theoretical and experimental investigations of gear-rattling , 1991 .