Dynamical modeling and experimental validation for tooth pitting and spalling in spur gears

Abstract Dynamical modeling of a gear system with faults has been an important research topic for understanding fault features and their associated fault vibration mechanisms. Due to the complicated structures and intricate interactions between the components of the gear system, the fault vibration features and corresponding vibration mechanisms due to tooth pitting and spalling remain mostly unknown. This paper proposes a novel spur gear dynamical model, validated by various experimental tests, to analytically investigate the effects of tooth pitting and spalling on the vibration responses of a gear transmission. The proposed dynamical model considers the effects of tooth surface roughness changes and geometric deviations due to pitting and spalling, and also incorporates Time Varying Mesh Stiffness (TVMS), a time-varying load sharing ratio, as well as dynamic tooth contact friction forces, friction moments and dynamic mesh damping ratios. The proposed gear dynamical model is validated by comparison with responses obtained from experimental test rig under different conditions. Comparisons indicate that the responses of the proposed dynamical model are consistent with experimental results, in both time and frequency domains under different rotation speeds and fault severity conditions.

[1]  Ahmet Kahraman,et al.  Prediction of Mechanical Efficiency of Parallel-Axis Gear Pairs , 2007 .

[2]  Yang Luo,et al.  Design and optimization of wheel-legged robot: Rolling-Wolf , 2014 .

[3]  Bangchun Wen,et al.  Time-varying mesh stiffness calculation of spur gears with spalling defect , 2016 .

[4]  Ian Howard,et al.  Comparison of localised spalling and crack damage from dynamic modelling of spur gear vibrations , 2006 .

[5]  T. F. Conry,et al.  The Effects of Surface Irregularities on the Elastohydrodynamic Lubrication of Sliding Line Contacts. Part I—Single Irregularities , 1984 .

[6]  Alfonso Fernández del Rincón,et al.  Effect of cracks and pitting defects on gear meshing , 2012 .

[7]  R. Nordmann,et al.  Identification of Stiffness and Damping Coefficients of Journal Bearings by Means of the Impact Method , 1984 .

[8]  P.J.L. Fernandes,et al.  Surface contact fatigue failures in gears , 1997 .

[9]  M. Khonsari,et al.  Theoretical and experimental investigation of traction coefficient in line-contact EHL of rough surfaces , 2014 .

[10]  Rui Ma,et al.  Research on dynamics and fault mechanism of spur gear pair with spalling defect , 2012 .

[11]  Paresh Girdhar.  Practical Machinery Vibration Analysis and Predictive Maintenance , 2004 .

[12]  Xianghe Peng,et al.  Survey of nonlinear vibration of gear transmission systems , 2003 .

[13]  Sheng Li,et al.  A spur gear mesh interface damping model based on elastohydrodynamic contact behaviour , 2011 .

[14]  Giorgio Dalpiaz,et al.  Effectiveness and Sensitivity of Vibration Processing Techniques for Local Fault Detection in Gears , 2000 .

[15]  Ming Liang,et al.  Evaluation of the time-varying mesh stiffness for gears with tooth spalls with curved-bottom features , 2018, Engineering Failure Analysis.

[16]  Guillermo E. Morales-Espejel,et al.  Prediction of micropitting damage in gear teeth contacts considering the concurrent effects of surface fatigue and mild wear , 2018 .

[17]  D. C. H. Yang,et al.  A Rotary Model for Spur Gear Dynamics , 1985 .

[18]  Robert B. Randall,et al.  A New Method of Modeling Gear Faults , 1982 .

[19]  P. Velex,et al.  Modelling of damping in lubricated line contacts – Applications to spur gear dynamic simulations , 2016 .

[20]  Natalie Baddour,et al.  Effects of gear center distance variation on time varying mesh stiffness of a spur gear pair , 2017 .

[21]  Sheng Li,et al.  A tribo-dynamic model of a spur gear pair , 2013 .

[22]  Anand Parey,et al.  Time varying mesh stiffness calculation of spur gear pair considering sliding friction and spalling defects , 2016 .

[23]  M. Khonsari,et al.  Application of Transient Elastohydrodynamic Lubrication Analysis for Gear Transmissions , 1995 .

[24]  Michael M. Khonsari,et al.  Film Thickness and Asperity Load Formulas for Line-Contact Elastohydrodynamic Lubrication With Provision for Surface Roughness , 2012 .

[25]  Ming J. Zuo,et al.  Spur Gear Tooth Pitting Propagation Assessment Using Model-based Analysis , 2017, Chinese Journal of Mechanical Engineering.

[26]  S. Yuan,et al.  Analysis of Lubricating Performance for Involute Gear Based on Dynamic Loading Theory , 2012 .

[27]  Shawki A. Abouel-seoud,et al.  Influence of Tooth Pitting and Cracking on Gear Meshing Stiffness and Dynamic Response of Wind Turbine Gearbox , 2012 .

[28]  Robert G. Parker,et al.  Vibro-acoustic propagation of gear dynamics in a gear-bearing-housing system , 2014 .

[29]  Y. Shao,et al.  Dynamic characteristics of helical gears under sliding friction with spalling defect , 2014 .

[30]  Hsiang Hsi Lin,et al.  A Parametric Study of Spur Gear Dynamics , 1998 .

[31]  Ming J. Zuo,et al.  The influence of tooth pitting on the mesh stiffness of a pair of external spur gears , 2016 .

[32]  D. Townsend,et al.  Analysis of the effects of surface pitting and wear on the vibration of a gear transmission system , 1996 .

[33]  J. Tarpani,et al.  Surface contact fatigue failure of a case hardened pinion shaft , 2014 .

[34]  Sheng Li,et al.  Influence of dynamic behaviour on elastohydrodynamic lubrication of spur gears , 2011 .

[35]  P. D. McFadden,et al.  Effect of transmission path on measured gear vibration , 1986 .

[36]  Michael M. Khonsari,et al.  Performance of Spur Gears Considering Surface Roughness and Shear Thinning Lubricant , 2008 .

[37]  J. W. Evans,et al.  An Extended Model for Determining Dynamic Loads in Spur Gearing , 1981 .

[38]  Ming J. Zuo,et al.  Dynamic modeling of gearbox faults: A review , 2018 .

[39]  Wenyi Wang,et al.  EARLY DETECTION OF GEAR TOOTH CRACKING USING THE RESONANCE DEMODULATION TECHNIQUE , 2001 .

[40]  Ming J. Zuo,et al.  Vibration signal modeling of a planetary gear set for tooth crack detection , 2015 .

[41]  Michael M. Khonsari,et al.  Mixed elastohydrodynamic lubrication line-contact formulas with different surface patterns , 2014 .

[42]  P. M. Ku,et al.  The Effect of Lubricants on Gear Tooth Surface Fatigue , 1958 .

[43]  Aiqiang Zhang,et al.  A study of spur gear pitting under EHL conditions: Theoretical analysis and experiments , 2016 .

[44]  Ming Liang,et al.  Performance Assessment of Gear Condition Indicators in Detecting Progressive Gear Tooth Crack , 2017 .

[45]  Philippe Velex,et al.  Contribution of Gear Body to Tooth Deflections—A New Bidimensional Analytical Formula , 2004 .

[46]  Sheng Li,et al.  A micro-pitting model for spur gear contacts , 2014 .