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The purpose of this paper is to investigate the dynamic responses of a spur gear pair with unloaded static transmission error (STE) excitation numerically and experimentally and the influences of the system factors including mesh stiffness, error excitation and torque on the dynamic transmission error (DTE).

A simple lumped parameters dynamic model of a gear pair considering time-varying mesh stiffness, backlash and unloaded STE excitation is developed. The STE is calculated from the measured tooth profile deviation under the unloaded condition. A four-square gear test rig is designed to measure and analyze the DTE and vibration responses of the gear pair. The dynamic responses of the gear transmission are studied numerically and experimentally.

The predicted numerical DTE matches well with the experimental results. When the real unloaded STE excitation without any approximation is used, the dynamic response is dominated by the mesh frequency and its high order harmonic components, which may not be result caused by the assembling error. The sub-harmonic and super-harmonic resonant behaviors are excited because of the high order harmonic components of STE. It will not certainly prevent the separations of mesh teeth when the gear pair is under the condition of high speed and heavy load.

This study helps to improve the modeling method of the dynamic analysis of spur gear transmission and provide some reference for the understanding of the influence of mesh stiffness, STE excitation and system torque on the vibration behaviors.

The finite element method has been increasingly applied in stress, thermal and dynamic analysis of gear transmissions. Preparing the models with different design and modification parameters for the finite element analysis is a time-consuming and highly skilled burden.

To simplify the preprocessing work of the analysis, a parametric finite element modeling method for spur and helical gears including profile and lead modification is developed. The information about the nodes and elements is obtained and exported into the finite element software to generate the finite element model of the gear automatically.

By using the three-dimensional finite element tooth contact analysis method, the effects of tooth modifications on the transmission error and contact stress of spur and helical gears are presented.

The results demonstrate that the proposed method is useful for verifying the modification parameters of spur and helical gears in the case of deformations and misalignments.

The paper is devoted to presenting a systematic investigation on the mechanical model and nonlinear dynamic characteristics of spur gear system with and without input shaft crack.

Considering the backlash, load-distribution, time-varying meshing stiffness and sliding friction, the modelling of a 5DOF gear system is proposed. Likewise, stiffness and damping models under elastohydrodynamic lubrication are developed, and sliding friction between gear pair is also outlined. In particular, a cracked input shaft which affects the support stiffness is presented, and breathing crack in keyway is adopted. On this basis, the dynamic responses of a gear system with and without input shaft crack are examined using numerical method, and some classical response diagrams are given, illustrating the effect of the important parameters on the gear system.

Dynamic simulation demonstrates that there exist periodic, quasi-periodic and chaotic motions in the gear system, and rational speed of the gear pair has noteworthy effects on vibration characteristic. Besides, comparison between healthy and cracked condition of input shaft indicates that occurring of crack convert periodic motion to quasi-periodic or chaotic motion.

The results give an understanding of the operating conditions under which undesirable dynamic behavior occurs, and provide some useful information to design and diagnose such gear system with crack fault.

Gear transmissions are widely utilized in practice. This paper aims to uncouple the crack feature from the cracked time-varying mesh stiffness (TVMS) and investigate the effects of the crack on the nonlinear dynamics of a spur gear pair.

An approximate method to simulate the cracked TVMS is proposed by using an amplitude modulation function. The ratio of mesh stiffness loss is introduced to estimate the TVMS with different crack depths and angles. The dynamic responses are obtained by solving a torsional model which takes the non-loaded static transmission error, the backlash and the cracked TVMS into account. By using the bifurcation diagram, the largest Lyapunov exponent (LLE) and dynamic mesh force, the influences of crack on nonlinear behaviors are examined. The dynamic characteristics are identified from the phase diagram, Poincaré map, dynamic mesh force, time series and FFT spectra.

The comparison between the healthy and cracked gear pairs indicates that the crack affects the system motions, such as the obvious changes of impact force and unpredictable instability. Besides, the additive and difference combination frequencies can be found in periodic-1 and -2 motions, but they are covered in periodic-3 and chaotic motions. Deeper crack is an important determinant of the nonlinear behaviors at a higher speed.

The research provides an interesting perspective on cracked TVMS and reveals the connection between crack and nonlinear behaviors of the gear pairs.

The purpose of this paper is to investigate the thermal elastohydrodynamic lubrication (TEHL) flash temperature of the helical gear pairs considering profile modification.

A flash temperature model of the helical gear pair considering the profile modification is proposed based on the TEHL and meshing theories. In doing so, the slicing, fast Fourier transform and chase-after methods are applied to accurately and rapidly obtain the flash temperature of the gear pair. Then, the effects of the modification, input torque and rotation speed on the flash temperature are studied.

With the increment of the tip relief amount, the flash temperature of the helical gear pair with the axial modification decreases first and then increases, and the meshing position of the maximum flash temperature moves toward the pitch point. Moreover, reducing the input torque or increasing the rotation speed can efficiently reduce the TEHL flash temperature.

This work is a valuable reference for the profile design and optimization of the helical gears to avoid the excessive flash temperature.

The purpose of this paper is to use a combination of numerical simulation and experiment to evaluate the performance of laser surface texturing (LST) in the field of gear lubrication, and to more accurately predict the lubrication characteristics of different surfaces.

The method used in this paper is developed on the basis of the deterministic solution of the three-dimensional (3D) mixed elasto-hydrodynamic lubrication (EHL) model and the model parameters are corrected by friction test. The film pressure, film thickness and friction coefficient of different micro-textured tooth surfaces are predicted on the basis of accurate 3D mixed EHL models.

The results demonstrate that the micro-texture structure of the tooth surface can increase the local film thickness and enhance the lubricating performance of the tooth surface without drastically reducing the contact fatigue life. The stress distribution and friction characteristics of the tooth surface can be optimized by adjusting the micro-texture arrangement and the size of the micro-textures.

A new evaluation method using a 3D hybrid EHL model and friction test to predict the lubrication characteristics of LST is proposed, which can effectively improve the processing economy and save time.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-11-2020-0423

The aim of this paper is to present a theoretical model to simulate the dynamic behavior of a spur gear, taking into account its ball bearings defects.

The proposed model is based on the implicit Newmark‐β with Newton‐Raphson numerical integration technique in order to analyze the impact of the worn bearings on the non linear dynamic behavior of one stage spur gear transmission system.

The dynamic behavior of spur gear is studied taking into account ball bearings defects thanks to the proposed model.

A new numerical model is proposed to simulate the dynamic behavior of rotating spur gear system taking into account both waviness and backlash defects.

The purpose of this study is to investigate the tribological performance of helical gear pairs with consideration of the properties of non-Newtonian lubricant and the real three-dimensional (3D) topography of tooth flanks.

Based on the mixed elastohydrodynamic lubrication (EHL) theory for infinite line contact, this paper proposes a complete model for involute helical gear pairs considering the real 3D topography of tooth flanks and the properties of non-Newtonian lubricant. Film thickness, contact load and contact area ratios at the mid-point of contact line are studied for each angular displacement of pinion. Both the total friction coefficient and surface flash temperature are calculated after obtaining the values of pressure and subsurface stress. Then, the influences of input parameters including rotational speed and power are investigated.

During the meshing process, contact load ratio and area ratio of the two rough surface cases first increase and then decrease; the maximum flash temperature rise (MFTR) on the gear is lower than that on the pinion first, but later the situation converses. For cylindrical gears, on the plane of action, there is a point or a line where the instantaneous friction reduces to a minimum value in a sudden, as the sliding–rolling ratio becomes zero. When rotational speed increases, film thickness becomes larger, and meanwhile, contact load ratio, coefficient of friction and MFTR gradually reduce.

A comprehensive analysis is conducted and a computer program is developed for meshing geometry, kinematics, tooth contact, mixed EHL characteristics, friction, FTR and subsurface stress of involute helical gear pairs. Besides, a numerical simulation model is developed, which can be used to analyze mixed lubrication with 3D machined roughness under a wide range of operating conditions.

This paper aims to investigate the effect of misalignment on wear of spur gears and on oil degradation using online sensors.

The misalignment effect on gears is created through a self-alignment bearing, and is measured using laser alignment system. Several online sensors such as Fe-concentration sensor, moisture sensor, oil condition sensor, oil temperature sensor and metallic particle sensor are installed in the gear test rig to monitor lubricant quality and wear debris in real time to assess gearbox failure.

Offset and angular misalignments are detected in both vertical and horizontal planes. The failure of misaligned gear is observed at both the ends and on both the surfaces of the gear teeth. Larger-size ferrous and non-ferrous particles are traced by metallic particle sensor due to gear and seal wear caused by misalignment. Scanning electron microscope (SEM) images examine chuck, spherical and flat platelet particles, and confirm the presence of fatigue (pitting) and adhesion (scuffing) wear mechanism. Energy-dispersive X-ray spectroscopy analysis of SEM particles traces carbon (C) and iron (Fe) elements due to gear failure.

Gear misalignment is one of the major causes of gearbox failure and the lubricant analysis is as important as wear debris analysis. A reliable online gearbox condition monitoring system is developed by integrating wear and oil analyses for misaligned spur gear pair in contact.

As the transmission component of a locomotive, the traction gear pair system has a direct effect on the stability and reliability of the whole machine. This paper aims to provide a detailed dynamic analysis for the traction system under internal and external excitations by numerical simulation.

A non-linear dynamic model of locomotive traction gear pair system is proposed, where the comprehensive time-varying meshing stiffness is obtained through the Ishikawa formula method and verified by the energy method, and then the sliding friction excitation is analyzed based on the location of the contact line. Meantime, the adhesion torque is constructed as a function of the adhesion-slip feature between wheelset and rail. Through Runge–Kutta numerical method, the system responses are studied with varying bifurcation parameters consisting of exciting frequency, load fluctuation, gear backlash, error fluctuation and friction coefficient. The dynamic behaviors of the system are analyzed and discussed from bifurcation diagram, time history, spectrum plot, phase portrait, Poincaré map and three-dimensional frequency spectrum.

The analysis results reveal that as control parameters vary the system experiences complex transition among a diverse range of motion states such as one-periodic, multi-periodic and chaotic motions. Specifically, the significant difference in system bifurcation characteristics can be observed under different adhesion conditions. The suitable gear backlash and error fluctuation can avoid the chaotic motion, and thus, reduce the vibration amplitude of the system. Similarly, the increasing friction coefficient can also suppress the unstable state and improve the stability of the system.

The numerical results may provide a systemic understanding of dynamic characteristics and present some available information to design and optimize the transmission performance of the locomotive traction system.