The study about planetary gearbox virtual prototyping with nonlinear gear contact characteristics

Abstract

The virtual prototypes of gear transmission system built in most multi-body dynamic software have difficulties in describing the gear mesh characteristics. The gear mesh contact is modelled as rigid contact and this is not accurate for the gear mesh contact, which is elastic or flexible. The gear contact formula used in the multi-body dynamic software does not reveal the gear contact nonlinear stiffness characteristic. The model built with gear meshing contact is difficult to solve because of its time-consuming algorithm. In the paper a new method is put forward to build the virtual prototype of planetary gearbox system according to the nonlinear mesh stiffness and mesh phase obtained through FEM models. This new FEM method of gear mesh stiffness calculation is much more accurate than the common formulas. The gear mesh nonlinear stiffness of sun gear- pinion and pinion-ring gear of all the planetary gear sets in gearbox are obtained through MATALB code, which is used to read and plot the analyzing result data. The gear mesh phase differences between different pinions with suns or rings of different planetary gear set can be also obtained. With all these data modelled in simulink (or other software) and integrated with the multi-body dynamic planetary gearbox model and the gear meshing contact problem in multi-body gear models is solved easily and accurately. The interfaces for gear mesh stiffness and mesh phases are designed for multi-body dynamic model and simulink. The nonlinear planetary gear set prototyping models are integrated to become the whole planetary gear box model and the whole vehicle system model built in multi-body dynamic software can be integrated to simulate different duty conditions. At last high speed input is put into the nonlinear planetary transmission model and the different duty cases are simulated. The dynamic characteristics of different parts are obtained. The dynamic characteristic comparison between nonlinear and linear models is made. It solves the difficulty of gear contact simulation in multi-body dynamic model and provides a new method in gear mesh stiffness calculation, which exports simulationX (or other software) model of nonlinear gear stiffness to replace that in multi-body dynamic model and succeeds in integrating planetary gear transmission with other parts of the vehicle. According to the simulation results, the conclusion can be made that the nonlinear modelling method for planetary gearbox is reliable and practical. It can be used to evaluate vibration characteristic of planetary gear transmission with high speed input