Dynamic reduction technique for nonlinear analysis of spur gear pairs

In this study the dynamic response of a spur gear pair is analyzed using a novel nonlinear approach. The actual rolling motion and engagement of the system is simulated using a set of reduced order models obtained in a pre-processing phase using the minimal amount of master degrees of freedom without loss of accuracy or generality. The flexibility of the gear bodies is included by a refined finite element model, and no geometry simplification is introduced while also retaining all nonlinearity sources. To reduce the computational cost the time-varying mesh stiffness is also pre-computed and used depending on the instantaneous loading conditions. Contact loss is also taken into account, and reconnection events are treated as vibro impacts. The results are compared against high quality and demanding experimental results with a computational cost several orders of magnitude lower than models with similar accuracy. Different loading conditions are investigated during the sweep-up and down maneuvers. Mainly, the dynamic transmission error is analyzed, showing remarkable agreement with the test campaign’s results. Different nonlinear phenomena such as hysteretic jumps and sub- and super-harmonic resonances are correctly predicted by the proposed model in terms of both frequency and amplitude. This method allows quick and accurate nonlinear analyses overcoming current limitations and is open to further complications to include other components and effects.