Abstract
The gear is one of the important parts of a rotary gearbox. Once catastrophic gear failure occurs, it will cause a great threat to production and life safety. The crack is an important failure factor causing changes in time-varying stiffness and vibration response. It is difficult to effectively identify the vibration response and meshing stiffness changes when there is a fine crack in the gear. Therefore, it is of great importance to improve the accuracy of meshing stiffness calculation and dynamic simulations under micro-cracks. Investigations of meshing stiffness and the vibration response of a gearbox is almost all about fixed gear shape parameters. However, the actual production process of gear system needs to change gear shape parameters. In this paper, the meshing stiffness and vibration response of the dynamic simulation signals of gear teeth with different crack depths at different tooth shape parameters (the pressure angle, the modulus, and the tooth number) were calculated, respectively. The influence of cracks on the vibration response was investigated by the fault detection indicators, the Root Mean Square (RMS), the kurtosis, and the crest factor. The result shows that when the pressure angle and modulus change, the vibration response changes erratically. However, when the tooth numbers change, the vibration response changes regularly. The results could be a guide for choosing gears in different shape parameters when system stability is the aim.
Highlights
The gearbox is the key unit of modern machinery and has been widely used in all kinds of engineering situations
Meshing stiffness is the ability of the teeth to resist deformation during meshing, and it is the key factor of gear vibration response
The vibration response of the gear system could be obtained in the dynamic model, as shown in Figure 5, and the main parameters of the gear transmission system are listed in Tables 3 and 4
Summary
The gearbox is the key unit of modern machinery and has been widely used in all kinds of engineering situations. The effect of different types of cracks on the dynamic responses was investigated by Chen [17] by taking the fillet-foundation stiffness into account On this basis, Cui et al [18] proposed a quantitative trend fault diagnosis method of a coupling gearbox based on Sparsogram and Lempel-Ziv. The performance is much better on the quantitative diagnosis of cracked components. An improved method, which is in reference to the cutting process of a gear tooth, was proposed by Ma [21,22] to calculate precisely the stiffness between the root circle and the base circle. In this paper, based on the rolling angle of cutting tools, a ‘universal equation of gear profile’ is introduced to investigate the changing behaviors of meshing stiffness and vibration response of a gear system under different depths and angles of cracks in the tooth root. Meshing Stiffness and Vibration Response for Cracked Gears in Different Shape Parameters
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