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Proc.

ofthe4thNationalConferenceonEmergingTrendsinMechanicalEngineering,March1819,2011
G.H.PatelCollegeofEngineering&Technology,V.V.Nagar388120,Gujarat,India
ISBN:9788190937634

Effect of Time Varying Mesh Stiffness of Gearing for Dynamic


Characterization
R.I. Patel 1*, N.V. Oza 2, S.S. Pathan3
1. Pursuing M.E. Mechanical Engg. L.D. College of Engineering, Ahmedabad.
2. Pursuing M.E. Mechanical Engg. L.D. College of Engineering , Ahmedabad.
3. Sr. Lecturer in Mechanical Engg. L.D. College of Engineering , Ahmedabad.
*
Corresponding author (e-mail: rip111176@yahoo.com )

In this paper, concept of experimental modal analysis is discussed to derive dynamic


characteristics of gearbox. Dynamic properties (time varying mesh stiffness, natural
frequency, mode shape and resonance) are calculated using MATLAB program for un-
damped gear system. The dynamic simulation model is developed using equation of
motion. Frequency Response Function (FRF) method is used in the derivation of 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. Results obtained are predictions of
functional behaviour of dynamic properties. 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. The effects of mesh stiffness
parameters, including stiffness variation amplitudes, mesh frequencies, contact ratios,
and mesh phasing, on the gears are analytically identified. Mesh stiffness variation is
approximated by Fourier series.

Keywords: Modal analysis; Time Varying Mesh Stiffness; Modeling and simulation.

1. Introduction

The undesirable noise and vibration caused by gears in a large variety of machine has
motivated the research to uncover the fundamental sources. Accurate dynamic mathematical model
of a power transmission system is essential for simulating reliably the dynamic characteristics. Such a
model would allow in improving the dynamic design at the computer level resulting in an optimized
design apart from savings in terms of money and time.

Vibration and noise reduction is a major concern in power train and gearing applications.
Gear analysis is required for improved performance requirements, such as high load capacity, high
endurance, low cost, long life and high speed. It is very important to compute the dynamic
transmission errors to predict gear vibrations and increase gear life. 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. The parametric excitation from the time-varying mesh stiffness causes instability, loss of
contact and severe vibration under certain operating conditions. Furthermore, mesh stiffness variation
directly affects tooth deflections and transmission error. The varying mesh stiffness depends on
number of instantaneous contact and location of corresponding contact point [1].

The objective of this study is to analyse the operation parameters in two mesh multi gear
system. The two meshes can have different mesh frequencies, amplitudes of mesh stiffness variation,
contact ratios, and mesh phasing. The two-stage gear systems and mesh stiffness modelling are
introduced first.
Gearbox vibration monitoring for fault detection and diagnosis is one of the important tasks in
industries. Recent trends in dynamic analysis are extremely focused on better performance and life of
power transmission system [2].

Dynamic modelling of gearing is useful tool to study the vibration response of geared system
under the influence of various gear parameters and operating conditions. An approach is given here
in order to explore the importance of time varying mesh stiffness.
EMA has become an attractive tool to extract modal parameters. Mathematical modelling and
simulation of such systems gives dynamic behaviour on hand prior to making prototypes. This type of

287
Proc.ofthe4thNationalConferenceonEmergingTrendsinMechanicalEngineering,March1819,2011
G.H.PatelCollegeofEngineering&Technology,V.V.Nagar388120,Gujarat,India
ISBN:9788190937634

analysis helps designers in early prediction of dynamic properties of transmission system in design
stage itself. Their life and performance can be improved simultaneously cutting down the cost. Gear
system is a complex non-linear model and needs more research work in this area. Increasing use of
power transmission by gears in industries requires reduced noise and vibrations for human comfort
and efficient performance of plants.

2. Methodology

EMA is used to determine resonant vibration in gear system. In EMA, a mode of vibration is
defined by three parameters; modal frequency, modal damping and mode shape. A set of modal
parameters can completely describe the dynamic behaviour of a gear structure. This set of
parameters is known as a modal model for the structure. Modes (or resonances) are inherent
properties of a structure. Resonances are determined by the material properties (mass, stiffness, and
damping properties), and boundary conditions of the structure. If either the material properties or the
boundary conditions of a structure change, its modes will change. For instance, if mass is added to a
vertical pump, it will vibrate differently because its modes have changed.

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. Resonant vibration typically amplifies the vibration response far beyond the level
deflection, stress, and strain caused by static loading. At certain natural frequencies of the structure
(its modal frequencies), a small amount of input force can cause a very large response.

2.1 Mathematical Model

Two stage gear trains have three-gear and four-gear configurations as shown in figure 1. Only
rotational vibrations 1 , 2 and 3 relative to rigid body gear rotations are considered. The input shaft
has torsional stiffness kL0 and is anchored with body rotating at constant speed such as driving motor.
The intermediate shaft connecting gears 2 and 4 is assumed rigid, which is reasonable for the typical
case of gears 2 and 4 being immediately adjacent or made from one piece. The tooth meshes are
modelled as linear springs with stiffness kL1, KL2 [1].

Figure 1 Two-stage gear system with Figure 2 Dynamic model for meshing gear pairs
[2]
(a) four gears and (b) three gears chains [1]

The gears have base radii ri, i =1, 2, 3, 4. The equivalent masses are m1=I1 /r12, m2=I2 /r22, and
m3= I3 /r32, where Ii are the moments of inertia of the gears and their connected shafts, =r4/r2 for
four gear chain and =1 for three gear chains. The equivalent stiffnesses are k0=kL0 /r12, k1=kL1, and
k2= kL2. The shaft/gear rotations are measured by the base radius deflections x1= 1 r1, x2= 2 r2,
2

and x3= 3 r3 / [1]. The stiffness of gear meshing pair basically depends on three components, gear
body, tooth and contact zone. The effect of gear body remains constant. While bending of tooth,
shear deformation and axial compression at contact area are varying. Hence there is a periodic
variation in 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].

288
Proc.ofthe4thNationalConferenceonEmergingTrendsinMechanicalEngineering,March1819,2011
G.H.PatelCollegeofEngineering&Technology,V.V.Nagar388120,Gujarat,India
ISBN:9788190937634

The system stability is governed by the free vibration equation


Mq&& + [ K 0 + K v (t )]q = 0
T
Where q=[x1, x2, x3] and M=diag [m1, m2, m3] is the inertia matrix. 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 g 2 kg2 K v (t ) = k v1 k v1 + k v 2 kv 2
0 kg2 kg2 0 kv 2 kv 2
Where k gi and kvi (t ) are the mean and time varying component of the mesh stiffnesses.
ki (t ) = k gi + kvi (t )
The variational part k vi (t ) are periodic at the mesh frequency i and expressed in Fourier
series as

kvi (t ) = 2k ai (ai( s ) sin si t + bi( s ) cos si t ),



i =1, 2 [1].
s =1

Where 2kai is the peak to peak amplitude of stiffness kvi . The mesh frequencies 1 and 2
are related by 1 = R 2 , where R = 2
Z and Z2 and Z4 are the number of teeth on gear 2 and 4.
Z4
Note when R=1, 1 = 2 for three gear systems. Meshing frequency is a product of angular speed
and number of teeth on teeth on gear. Mesh stiffness variation is obtained through measurement,
calculation or simple specification such as sinusoidal or rectangular wave [1]. A mathematical model
for tooth is shown in figure 4. Change in contact stress during gear mesh causes stiffness variation.
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]. In this study, the k vi , are specified as rectangular
i
waves with variational amplitudes k ai , period Ti = , contact ratio ci, and phasing angles piTi as
2
shown in figure 3. Thus,

sin[s (ci 2 pi )]sin(sci ),


2
ai( s ) =
s
= cos[s (ci 2 pi )]sin(sci ) .
2
bi( s )
s
For s=1, 2, 3n. without loss of generality, mesh phasing can be specified as p1=0 and p2=h. In
practice, the first three or four terms of Fourier series can reasonably approximate the mesh stiffness
variation. Here in this study, first four terms are used to approximate the variation in stiffness [1].

Figure 3 modelling of varying mesh stiffnesses [1] Figure 4 modelling of tooth [3]

For time invariant case, the eigenvalue problem associated with motion equation is
K 0i = i2 Mi , Where, i are the natural frequencies.

289
Proc.ofthe4thNationalConferenceonEmergingTrendsinMechanicalEngineering,March1819,2011
G.H.PatelCollegeofEngineering&Technology,V.V.Nagar388120,Gujarat,India
ISBN:9788190937634

The vibration modes i are normalised as,


T = ; T = , [5, 6]
Where = [1 ,2 , 3 ] , = 0 + v (t ) and applying modal transformation q = u
The mass normalised eigenvectors are obtained which are designated as having the particular
property. Using the relationship between the mass normalised mode shape for mode i, i.e. [i ] and its
more general form [ i ] is considered. A modal model is constructed using the orthogonality principle
[5,6].
The frequency response function (FRF) is calculated by solving the equation
( ) = ([K ] 2 [M ])
1
.
Where, is an excitation frequency.

2.2 Assumption for MATLAB simulation

Varying mesh stiffness is approximated considering Fourier series rectangular waveforms.


Two stage speed reduction with four gear system is used.
Damping is neglected.

2.3 Procedure

Obtain a suitable (admissible) set of test data.


Compute the time varying mesh stiffness using Fourier series.
Compute Global Stiffness Matrix.
Using Global stiffness and Mass matrix derive Eigen-values and Eigen-vectors.
Repeat the procedure for suitable iterations.
Determine natural frequencies and mode shape vectors.
Tabulate time varying mesh stiffnesses versus time.
Tabulate natural frequencies versus time.
Compute Frequency Response Function (FRF).
Plot Varying mesh stiffness versus time.
Plot Frequency Response versus frequency on log-log scale.
Plot natural frequencies versus time.

Table 1 Parametric Data of Gear system used in computation

Sr. no Parameter Value


1 Equivalent masses m1= 1.0, m2 = 1.5, m3 = 3.5 kgs.
2 Average Mesh Stiffness Kg1= kg2 = 1000 N/m
3 Anchor Shaft Stiffness ko= 500 N/m
4 Contact Ratio c1= c2= 1.4
5 Mesh Phasing p1= 0, p2 =h=0.5
6 Peak to Peak Amplitude ka1 = ka2 =250 N/m
7 Mesh Frequencies 1 = 3014.4 2 = 1507.2 rad/sec

3. Results & Discussion

Dynamic modelling is done and MATLAB simulation is used to predict the dynamic
characteristics of a gearbox. Time varying mesh stiffness is plotted. Mesh stiffness variation with
relate to time is significant against average mesh stiffness. 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. Adjusting contact ratio can eliminate or reduce the size of parametric instabilities regions [1, 3 -
4].

290
Proc.ofthe4thNationalConferenceonEmergingTrendsinMechanicalEngineering,March1819,2011
G.H.PatelCollegeofEngineering&Technology,V.V.Nagar388120,Gujarat,India
ISBN:9788190937634

From the plot of FRF it can be 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. As
properties of the system under consideration are continuously varying with time, care should be taken
to design governing parameters. Impact of force and loss of contact during motion of gears are key
factors for noise and vibrations of gears. 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.

time varying mesh stiffness for gears pair 2


varying mesh stiffness for gears pair 1

300
300

200
200

100
100

0
0
0 5 10 15 20 25 30 35
0 5 10 15 20 25 30 35

Kv(2)
Kv(1)

-100 -100

-200 -200

-300 -300

-400 -400
time time

(a) Meshing of gears pair 1 (b) meshing of gears pair 2


Figure 5 plot of Varying mesh Stiffness versus time

(a) Time t=11.1sec where 3 =minimum (b) time t=14.4 sec where 3 =maximum
Figure 6 Frequency Response Function Plot

In the study of two stage speed reduction using four-gear systems, there are three degrees of
freedoms. The system has three natural frequencies and mode vectors, shown in figure 6. Natural
frequencies for various configurations are plotted against time. Figure 7 shows that second and third
natural frequencies are relatively changing more rapidly as compared to first natural frequency.
Second and third natural frequencies vary in the range of 24 to 30 rad/sec and 39 to 53 rad/sec. The
variation of these frequencies is noticed as periodic. This shows that speed of gearbox should be so
tuned that there should be no occurrence of resonance which may create excessive vibrations.

291
Proc.ofthe4thNationalConferenceonEmergingTrendsinMechanicalEngineering,March1819,2011
G.H.PatelCollegeofEngineering&Technology,V.V.Nagar388120,Gujarat,India
ISBN:9788190937634

natural frequencies Vs time

60.0000

50.0000

Wn1(rad/sec)
40.0000
Wn2(rad/sec)
Wn(i) rad/sec

Wn3(rad/sec)

30.0000

20.0000

10.0000

0.0000
0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0
time(sec)

Figure 7 Plot of Natural Frequencies versus time

Table 2 Range of natural frequencies:

Frequency (rad/sec) n1 n 2 n3
Maximum 7.5669 30.3028 52.5120
Minimum 6.6652 24.0051 39.8486
Average 7.2184 27.5662 47.7300
Frequency with In-variant Stiffness 7.2959 28.0029 47.7667

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, which is reported in literatures.

4. Conclusion

Modelling of a three stage gearbox is done. Prediction of natural frequencies of an undamped


gearbox is presented by considering the effect of time varying mesh stiffness using MATLAB. Due to
variation in mesh stiffness of the mating teeth, there occurs variation in natural frequencies. These
frequencies are varying periodically. Periodical variation of frequencies can be estimated using
Fourier series. Experimental work will be done in future to validate the model. The change in stiffness
of meshing teeth as the number of teeth in contact changes causes parametric instabilities and
severe vibration in gear systems. To visualize the effects of mesh stiffness parameters, i.e. stiffness
variation amplitudes; mesh frequencies; contact ratios; analytical identification is done for the
gearbox.

References

[1] Jian Lin, Robert G Parker, Mesh Stiffness Variation Instabilities in Two-Stage Gear
Systems, ASME Journal of Vibration and Acoustics JANUARY 2002, Vol. 124, pp 68-76
[2] Sejoong Oh, Karl Grosh, James R. Barber, Energy Conserving Equations of Motion for Gear
Systems, ASME Journal of Vibration and Acoustics APRIL 2005, Vol. 127, pp 208-212
[3] 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.

292
Proc.ofthe4thNationalConferenceonEmergingTrendsinMechanicalEngineering,March1819,2011
G.H.PatelCollegeofEngineering&Technology,V.V.Nagar388120,Gujarat,India
ISBN:9788190937634

[4] 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.
[5] T R Chandrupatla, A D Belegundu, Introduction to Finite Elements in Engineering, 3rd
Edition, PHI Learning Pvt. ltd., 2009
[6] S.S. Rao, Mechanical Vibrations, 4th Edition, Pearson education Pvt. ltd. 2006

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