Rafiq Maliha

Former Student, Mechanical Engineering Department, Middle East Technical University, Ankara 06531, Turkey

Nonlinear Dynamic Modeling of Gear-Shaft-Disk-Bearing Systems Using Finite Elements and Describing Functions
This study presents a new nonlinear dynamic model for a gear-shaft-disk-bearing system. A nonlinear dynamic model of a spur gear pair is coupled with linear nite element models of shafts carrying them, and with discrete models of bearings and disks. The nonlinear elasticity term resulting from backlash is expressed by a describing function, and a method developed in previous studies to determine multi harmonic responses of nonlinear multi-degree-of-freedom systems is employed for the solution. The excitations considered in the model are external static torque and internal excitation caused by mesh stiffness variation, gear errors and gear tooth prole modications. The model suggested and the solution method presented combine the versatility of modeling a shaft-bearingdisk system that can have any conguration without a limitation to the total degree of freedom, with the accuracy of a nonlinear gear mesh interface model that allows to predict jumps and double solutions in frequency response. Thus any single stage gear mesh conguration can be modeled easily and accurately. With the model developed it is possible to calculate dynamic gear loads, dynamic bearing forces, dynamic transmission error and bearing displacements. Theoretical results obtained by using the method suggested are compared with the experimental data available in literature, as well as with the theoretical values calculated by employing a previously developed nonlinear single degree of freedom model. DOI: 10.1115/1.1711819

ruer* Can U. Dog

Mechanical Engineering Department, Middle East Technical University, Ankara 06531, Turkey

zgu ven H. Nevzat O

Fellow ASME, Mechanical Engineering Department, Middle East Technical University, Ankara 06531, Turkey e-mail: ozguven@metu.edu.tr

Introduction

1.1 Previous Studies. Many researchers have been interested in gear dynamics since the 18th century. The main concern was to nd dynamic gear loads and dynamic forces on gear teeth. The models proposed differ from each other mainly in effects and degrees of freedom included, elements considered in the model ywheel, shaft, bearings, etc., the solution techniques used, the type of response calculated steady state response, transient response, type of excitation low frequency excitations such as torque variations, high frequency excitations due to static transmission error function and the effects included such as backlash, gear errors, tooth modications, etc. An extensive review of such zgu ven and Houser models, until the late 1980s, was given by O 1. Detailed literature surveys of Blankenship and Singh 2, and Velex 3 also give references to the gear dynamic models developed. The earlier studies on geared rotor dynamics go back to the 1960s. Seireg 4 investigated whirling of geared shafts experimentally. The model of Johnson 5 might be considered to be the rst attempt to include the constraints imposed by gears in rotor dynamics. Iida et al. 6 9 have published a series of papers between 1980 and 1986 on the coupled torsional-transverse vibrations of geared rotors. However, in all these studies the compliances of gear teeth, as well as all other nonlinear effects were ignored. Iwatsubo et al. 10 studied rotor dynamics of geared shafts by using constant mesh stiffness, neglecting tooth errors and backlash. Neriya et al. 11,12 used nite element formulation in the dynamic analysis of geared rotors by incorporating a discrete model of a gear pair into the mass and stiffness matrices of
*Presently at University of Hacettepe, Ankara, Turkey; e-mail: cdogruer@yahoo.com Contributed by the Design Automation Committee for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received February 2003; revised September 2003. Associate Editor: A. A. Shabana.

shafts. In these studies constant mesh stiffness was assumed and a zgu ven linear model was obtained. The nite element model of O zkan 13 for the dynamic analysis of rotor-bearing systems, and O which includes the effects of rotary inertia, gyroscopic moments, axial load, hysteric and viscous forms of internal damping and shear deformations, was later extended by Kahraman et al. 14 to include the coupling effects of a gear pair. In all geared rotor dynamic models which employ nite element modeling for the shafts, nonlinear effects due to geared connection were ignored, as otherwise it would require a considerable computational effort to solve a set of nonlinear differential equations for a multi-degreeof-freedom system with high order. A second group of gear dynamics studies include nonlinear and/or time varying effects due to gear coupling. Such studies make it possible to study the inuence of several gear errors, shape modications, mounting errors, etc., on gear dynamics. Earlier works in this group were discussed in the review paper of zgu ven and Houser 1. More recently, Velex and Maatar 15 O have studied the inuence of shape deviations and mounting errors on gear dynamics. Lin et al. 16,17 have investigated several prole modications and resulting dynamic loads. Blankenship and Singh 18,19 developed a comprehensive linear helical gear mesh interface dynamic model. Later, this helical gear mesh interface is used in the model of a multi-mesh gear train of Vinayak et al. 20. Vinayak and Singh 21 have extended this model by including the compliance of gear bodies. Further studies on multimesh systems include the works of Kahraman 22, Vinayak and Singh 23, Lim and Houser 24, Lim and Li 25, and Raclot and Velex 26. However, the models including shaft and bearing dynamics have large number of degrees of freedom and do not allow nonlinearities such as total loss of contact, and therefore amplitude jumps in frequency responses cannot be simulated with such gear dynamics models. Earlier experimental studies on dynamic response of spur gear pairs have been reported by Munro 27 and Kubo et al. 28. Recent experimental studies on gear dynamics were carried out by Transactions of the ASME

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Fig. 1 A typical geared rotor system

Baud and Velex 29, and Kahraman and Blankenship 30. The jump observed around the main resonance region in the dynamic response of a gear system, which is due to backlash, can be theoretically predicted if a nonlinear dynamic model that includes the effects of backlash and tooth separation is used. Several researchers, e.g. 3135, have included backlash in their dynamic models. However, this leads to nonlinear differential equations. Then, either time integration techniques have been used for the solution, or harmonic balance method has been applied when the model had a single degree of freedom 36,37. Although time integration techniques are appropriate for the analysis of such systems, when bearing and shaft dynamics are included and nite element modeling is employed, it may be very expensive to nd the steady state response by time integration. 1.2 Present Study. As can be seen above, the existing advanced models for gear dynamics either employ nite element modeling for shafts on exible bearings and thus have many degrees of freedom but do not include all of the effects that might be important for a gear dynamics system such as clearance that causes jumps and double solutions, gear errors, prole modication, internal excitation due to time variation of mesh stiffness, etc. or include such effects but restrict the total degree of freedom of the resulting highly nonlinear system and are generally developed for a xed conguration. In this present study, a geared rotor dynamics model that consists of nite element models of rotors, nonlinear discrete model of a gear pair, discrete models of bearings and disks on shafts is suggested. The model considers the excitation effects of time varying mesh stiffness, gear errors, and prole modications by zgu employing the loaded static transmission error method of O ven and Houser 34. The model can also easily be extended to include the clearance type of nonlinearities in bearings, as well as any type of nonlinearity in any element. The iterative solution zgu ven 38,39 in the method, developed rst by Budak and O early 1990s and later extended by Tanrikulu et al. 40, makes it possible to analyze large order discrete nonlinear systems under harmonic excitation. The method is very powerful especially for systems with local nonlinearities. In this method, a set of nonlinear ordinary differential equations is transformed into a set of nonlinear algebraic equations by employing harmonic balance method. Although an iterative technique is used in solution, it requires iteration only for those coordinates that are associated with nonlinear elements, which reduces the computational time drastically. The method is capable of including higher order harmonics as well. A typical geared rotor system is shown in Fig. 1. Yet, the computer program developed in this study is capable of analyzing any conguration that consists of a single stage spur gear pair, two shafts and any number of disks and exible bearings at any location. Moreover, complicated shaft geometries and nonuniformity can be handled since nite elements are used in modeling shafts. The degrees of freedom considered in a nonlinear spur gear model are the rotations of gears and the relative translation of the gear Journal of Mechanical Design

centers along the pressure line. The variable mesh stiffness, resulting from the change in the number of teeth in contact and from tooth prole, is included into the analysis by using constant mesh stiffness with a displacement excitation at the mesh point along the pressure line, which represents loaded static transmission error. In this study, loaded static transmission error is calculated by using the Load Distribution Program LDP version 10.1 that was developed at the OSU Gear Lab Gear Dynamics and Gear Noise Research Laboratory, Ohio State University. LDP is an output of series of research carried out at the OSU Gear Lab 41, and it calculates load distribution, transmission error, root and contact stresses, mesh stiffness, tooth force, etc., for a pair of spur or helical gears by considering bending of teeth in contact, local contact deections, torsional and bending deections of gear bodies, exibility of bearings, housings and shafts. It also includes the effects of all gear prole and spacing errors, prole modications and shaft misalignment errors. The computer code, Non-Linear Geared Rotor Dynamics NLGRD, developed in this study is capable of calculating dynamic gear loads, dynamic bearing forces and bearing vibrations, as well as making the modal analysis of the corresponding linear system. The mathematical model suggested and the computer program developed can take several important effects into account, such as various gear faults, prole modications, backlash, tooth separation, mesh and bearing damping.

Mathematical Model

2.1 Modeling of Rotors. A generic geared rotor system, which consists of a spur gear pair mounted on two exible shafts, supported by exible bearings is shown in Fig. 1. The basic elements of such a system are; exible shafts, rigid disks, exible bearings, and a gear pair. Assuming that the axial motions of shafts are negligible, each node in the nite element model of a shaft will have ve degrees of freedom. Then each nite rotor element has ten degrees of freedom. The rigid disks and gear blanks are modeled as ve degrees of freedom rigid elements, whereas exible bearings are modeled as two degrees of freedom elements. The equation of motion for a nite beam element can be written as 13
e e e e v K B e M te M r M T q q

1H
2 1H

e e e K B KT KA

2 1 H

e KC q e

f e

(1)

where dot denotes differentiation with respect to time, and nite rotor element matrices are given in Ref. 13. The force displacement relations for a bearing and a rigid disk can be written, respectively, as

CYY C ZY

CYZ C ZZ

b q

KYY K ZY

KYZ K ZZ

q b f b

(2) (3)

d d f d M td M r q

Assembling all element matrices of two shafts with those of bearings and disks, and then with spur gear mesh model that will be discussed in the next section, yields the equation of motion for the entire system as follows C q K qN f M q (4)

2.2 Spur Gear Mesh Model. A typical spur gear mesh shown in Fig. 2 is represented by a pair of rigid disks, which are coupled by a nonlinear spring that can be modeled by a nonlinear displacement function f p and a viscous damper with a damping coefcient of C m , both acting along the pressure line. Friction forces at the mesh point can be assumed to be negligible. Thus the MAY 2004, Vol. 126 535

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where I p and I g are the mass moment of inertia of pinion and gear, respectively. After some manipulations 42, the equations of motion for the three degree of freedom nonlinear dynamic model of a spur gear pair can be written in matrix form as

m eq 0 0

m eq mp 0

m eq 0 mg

f exc 0 0

Cm p y p Cm y g Cm

0 0 0

0 0 0

p k h f p p y p k h f p p y g k h f p p

(14)

where the total excitation force f exc is given by t f exc W exc m eq e W exc m eq T p T g (15) (16)

Fig. 2 Dynamic model of a spur gear mesh interface

It should be noted here that even the average mesh stiffness is used in the mesh modelEq. 14the internal excitation effect of the time variation of mesh stiffness is included into the analysis by using the loaded static transmission error as a displacement zgu ven and Houser 34 input into the system, as suggested by O and used in further studies.

transverse vibrations along the pressure line are uncoupled from those perpendicular to the pressure line. The damping coefcient can be assumed to be time-invariant. Considering the mesh model shown in Fig. 2, the relative displacement between two gears along the pressure line can be written as: p y p r p p y g r g g e t t (5)

Solution Method

where r p and r g are the base circle radii of pinion and gear, respectively, and p and g denote angular rotations of pinion and gear, respectively. The loaded static transmission error e ( t ) which includes the excitation effect of time variation of mesh stiffness as well 34 can be written in terms of its Fourier components as e t t

m1

a m cos mN p p t jb m sin mN p p t

(6)

where j is the unit imaginary number. Then, the differential equations for torsional vibrations of the gear pair can be written as p W 1r p T p I p g W 2r g T g I g where W 1 C m p k h f p p W 2 W 1 (9) (10) (7) (8)

W 1 and W 2 are the mesh forces on the driving and driven gears, respectively, f p ( p ) is the nonlinear displacement function representing backlash and k h is the average mesh stiffness. The viscous mesh damping coefcient C m can be expressed in terms of the equivalent mass m eq and viscous damping ratio as C m 2 m eq n (11) Here natural frequency n and equivalent mass m eq are dened as

In the model obtained for the whole system, nonlinearity is associated with only three degrees of freedom of the dynamic gear mesh interface namely, y g , y p and p ), since the models used for the shafts, bearings and disks are linear. The method rst sug zgu ven 38,39 and then developed further gested by Budak and O by Tanrikulu et al. 40 makes it possible to analyze a nonlinear multi degree of freedom system under harmonic excitation by using harmonic balance. The method has the advantage of handling systems with different congurations and with several different types of nonlinearities, by using a general formulation. Furthermore, a drastic reduction is obtained in computational time, especially when the nonlinearity is local. A similar concept have been also used by Royston and Singh 43 to analyze periodic response of mechanical systems with local nonlinearities, in which an order reduction is employed in order to reduce computational cost. Alternative methods for the dynamic analysis of multi degree of freedom systems with local nonlinearities were proposed by Cipra and Uicker 44,45, and Ren and Beards 46. However, in both of the methods suggested numerical integration is used in at least one phase of the solution. The method employed in this study avoids numerical integration as well as condensation of linear degrees of freedom, and uses multi harmonic balance. In this method the linear and nonlinear parts of the system are dealt with separately, the former being represented by a constant receptance matrix and the later by a quasilinear receptance matrix that is updated at each iteration. Thus the computational time is reduced signicantly without condensing any coordinate. The nonlinearity in the system is expressed as a nonlinear internal force vector N , of which nonzero part N 1 is given by k h f p p N 1 k h f p p k h f p p

(17)

n k h / m eq
m eq 536 Vol. 126, MAY 2004 I pI g 2 r2 I p g r gI g

(12) (13)

where the nonlinear function f p ( p ) see Fig. 2 can be expressed in harmonic form by using describing function m ( A ) as f p p

m0

m A P m e jm

(18)

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f p p

1 P0

f p p d P 0

X 2 22 1 F 2 21 X 1

(31)

m1

2 Pm

f p p sin m d P m e

substitution of which in Eq. 28 gives

jm

X 1 11 11 12 22 1 21 1
(19) F 1 12 22 1 F 2 (32) The right hand side of Eq. 32 contains the so-called nonlinearity matrix, 11 , which depends on the unknown vector X 1 , and therefore it should be recalculated in each iteration step in the solution process. However, it should be noted that in this technique, the size of nonlinear algebraic problem is reduced to the order of the nonlinearity matrix, which means that only a limited number of coordinates rather than all coordinates are recalculated in the iteration procedure, which reduces the computational time signicantly. Since there is no external harmonic force on the system, F 2 0 and Eq. 32 can be written as

Hence the nonzero part of the nonlinear internal force vector N m for the mth harmonic can be written as

N 1 m G 1 m e jm t
where

(20)

G 1 m

m A P m A k h P m 11 m Y g m A Yp

(21)
m

Here 11 m is the nonzero part of m and is given by

11 m

k h m k h m k h m

0 0 0

0 0 0

X 1 11 1 F 1
(22) where
11 12 22 1 21

(33)

(34)

Here, it should be noted that the nonlinear internal force vector is expressed in terms of the unknown response amplitudes. After substituting Eq. 20 and 21 into Eq. 4, the equations of motion of the system for the mth harmonic component of the periodic excitation can be written in frequency domain as
m 2 M j m C j H K m X m F m (23)

Alternatively, the response can be calculated by using the receptance matrix of the linear part of the system, , rather than the dynamic stiffness matrix of the linear part, by following the method given in reference 40. In order to express the solution in matrix form, the formulation given in reference 47 for nonproportionally damped systems can be extended to nonlinear systems, and thus the quasi-linear receptance matrix of the nonlinear system can be written as
11 I 11 11 1 11

or in a compact form, as

X m m F m

(35) (36) (37)

(24)

where m is the response level dependent quasi-linear receptance matrix of the system at frequency m and can be written as
m m 2 M j m C j H K m 1 (25)

12 21 I 11 11
T

12

22 22 21 11 12

As the quasi-linear receptance matrix is expressed in terms of m , which is composed of analytically obtained describing functions dened as a function of unknown response values, the solution requires an iterative procedure. The quasi-linearization presented above makes it possible to transform a set of nonlinear differential equations into a set of nonlinear complex algebraic equations. It should be noted that the nonlinearity of the whole set of coupled equations are due to the nonlinearity at the gear mesh, which directly affects only three coordinates. Therefore, it is possible to perform the iteration for only three equations with nonlinear terms when only a single harmonic is used, regardless the total number of degrees of freedom of the system, and then to solve the remaining linear set of equations directly. The procedure employed is explained below. Equation 23 can be rst rearranged as
m X m G m F m

(26)

where m is the linear dynamic stiffness matrix and G m is the amplitude vector of the nonlinear forces for the mth harmonic. Then it can be partitioned as follows in the following equations the subscript m is dropped for simplicity

11 21

12 22

X 1 G 1 F 1 X 2 0 F 2

Then X can be calculated from the quasi-linear receptance matrix obtained above by using Eq. 24. The alternative solution given above has the advantage of avoiding the inversion of matrix 22 which is a large order matrix, but instead it requires the computation of by modal summation. Therefore, it is the size of 22 which determines the choice of the formulation to be used in order to reduce computational time further. In both formulations given above, the equations are written for each harmonic of the loaded static transmission error. However as 11 is a function of p that is expressed in terms of all harmonic components considered, in order to calculate response at any harmonic, it is necessary to calculate all other harmonics simultaneously. Therefore, Eq. 33 represents 3( n 1) sets of nonlinear equations and they should be solved simultaneously, where n is the number of harmonics used to express loaded static transmission error in terms of its Fourier components. The linear response is used to form the nonlinearity matrix in the rst trial. The iteration is continued until the required accuracy is achieved. As can be seen from the above derivation, any other nonlinearity in the system, such as clearance at bearings, can easily be included into the model, which will just increase the size of the nonlinearity matrix 11 .

(27) (28) (29)

Comparisons With Experimental Results

11 X 1 12 X 2 G 1 F 1 21 X 1 22 X 2 F 2

In order to study the validity of the mathematical model presented, the theoretical results obtained by the method suggested are compared with the experimental results of Kubo 28 and Kahraman and Blankenship 30. 4.1 Case Study 1: Comparison With Kubos Experimental Results. Kubo et al. 28 used four-square spur gear test rig, which is shown in Fig. 3. Shafts and bearings were designed to be very stiff. Table 1 shows the values of the parameters used in MAY 2004, Vol. 126 537

where

G 1 11 X 1
Solving Eq. 29 for X 2 yields Journal of Mechanical Design

(30)

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Fig. 5 Comparison of the computational results obtained by NLGRD with Kubos experimental results. Upper and lower bounds of Kubos experimental results , NLGRD . Fig. 3 Generic model of Kubos experimental gear system used in Case Study 1

Kubos setup 3133. The loaded static transmission error calculated by LDP for two mesh cycles assuming there is no gear error is given in Fig. 4. The theoretically calculated dynamic factor in this study is dened as the dynamic to static load ratio DSLR while the dynamic factor DF measured by Kubo is the ratio of the dynamic

Table 1 Parameters of Kubos experimental setup Module mm Number of teeth Base diameter mm Outside diameter mm Root diameter mm Pitch diameter mm Face width mm Backlash mm Pressure angle deg Contact ratio Mesh stiffness N/m Amplitude of STE m Static load N I p (kgm2 ) I g (kgm2 ) I L (kgm2 ) I M (kgm2 ) Bearing stiffness N/m Bearing damping Ns/m Shaft damping ratio 4 25/25 94 108 90 100 15 0.1 20 1.56 0.2587E9 2.479 2295 0.1152E 2 0.1152E 2 0.1152E 2 0.5762E 2 0.3503E13 0.3503E6 0.005

to static tooth stresses. Therefore, theoretically calculated dynamic factors are not expected numerically be in exact match with experimentally measured values. Comparison of the theoretical results obtained by the method suggested in this work using 5 harmonics with Kubos experimental results and also with the DSLR calculated by using the zgu ven and Houser 34 are shown in Fig. 5 nonlinear model of O and Fig. 6, respectively. The later is referred to as DYTE Dynamic Transmission Error Program, which is the name of the computer code developed in Ref. 34, for convenience. It can be observed from Fig. 5 that the general trend obtained by the method suggested in this work is in very good agreement with Kubos experimental results. The jump observed in the experimental results is predicted theoretically quite accurately. The experimental results given by Kubo are the upper and lower bounds of the dynamic factors measured for eight teeth on pinion, whereas the theoretical values are the dynamic factors calculated with an upward and downward sweeps. The main resonance peak, as well as the peaks at subharmonic frequencies are calculated slightly higher, and the difference in the numerical values are mainly due to the fact that experimental values are dynamic factors based on tooth stresses, while the theoretical values are the dynamic factors dened as dynamic to static load ratios. It was also observed that using even only the fundamental harmonic yields results very similar to the ones presented in Fig. 5, except

Fig. 4 Loaded static transmission error used in Case Study 1

Fig. 6 Comparison of the computational results obtained by NLGRD with those obtained by DYTE for Kubos experimental system. DYTE , NLGRD .

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Table 2 Parameters of Kahraman and Blankenships experimental setup Number of Teeth Module mm Pressure Angle deg Gear Ratio Backlash mm Viscous Damping Coefcient Face width mm Whole depth mm Outside diameter mm Pitch diameter mm Base circle diameter mm Root diameter mm Involute contact ratio 50 3 20 1/1 0.015 0.01 20 7.66 156 150 140.95 140.68 1.56

Conclusions

Fig. 7 Generic model of experimental gear system used in Case Study 2

around the peaks at subharmonic frequencies which naturally cannot be predicted theoretically when only the rst harmonic of the excitation is considered. It can be concluded from the study of Fig. 6 that the model suggested yields results in agreement with the results of a nonlinear time varying gear dynamics model in which solution is obtained by direct numerical integration. It should be noted that in Kubos setup stiff bearings and shafts were used so that the torsional mode is dominant and primarily governed by the mesh stiffness, which means an accurate theoretical prediction can be made even with a model disregarding the shaft and bearing dynamics. This is probably why the two models give similar results. However, it is observed that the model presented in this work yields better results at sub harmonic frequencies, compared with those calculated by DYTE in which shaft and bearing dynamics are not included into the analysis. 4.2 Case Study 2: Comparison With Experimental Study of Kahraman and Blankenship. In a recent experimental study, Kahraman and Blankenship 30 investigated the nonlinear dynamic behavior of spur gears with clearance. In this experimental study, highly nonlinear behavior of the system due to clearance has been clearly observed. The theoretical results obtained by using the method suggested in this work for the experimental setup of Kahraman and Blankenship are compared with the experimental measurements in order to study the validity of the mathematical model developed for gear systems with high nonlinearity. The generic model used to represent the four-square gear test rig of Kahraman and Blankenship is shown in Fig. 7. The parameters of the experimental rig are given in Table 2. The root mean square value of the alternating components of the dynamic transmission error DTE is calculated at each frequency by using 5 harmonics. The theoretically calculated values are compared with the experimental results in Fig. 8. It can be observed that, although 1/3 subharmonic resonance frequency is predicted slightly higher than the experimental value and the peak value calculated at this subresonance is lower than the experimen1 tal result, both at resonance and 2 subharmonic resonance frequencies there is a good agreement between theoretically calculated and experimental values. Peak values are pretty accurately predicted, and experimentally observed jumps can theoretically be obtained with an acceptable accuracy. Journal of Mechanical Design

In this study, a nonlinear multi degree of freedom dynamic model for a spur gear pair on exible shafts with exible bearings is obtained, and then the method developed in previous studies 38 40 for multi harmonic vibration analysis of nonlinear systems with large degrees of freedom is employed for the solution of resulting nonlinear discrete differential equations. A nonlinear spur gear pair model with three degrees of freedom is used to couple the differential equations of motion of two shafts on any number of exible bearings with disks on them. Finite element modeling is used for accurate representation of shaft dynamics. The model includes external excitation due to static torque, as well as the internal excitation caused by mesh stiffness variation, gear errors and gear tooth prole modications. The excitation effects of both static transmission error due to several gear errors and tooth prole modications, and time variation of mesh stiffness are included into the dynamic analysis by using a displacement excitation at the mesh point that represents the loaded static transmission error function 34. The dynamic analysis yields dynamic gear loads, dynamic bearing forces, dynamic transmission error and bearing displacements. As the nonlinearity stemming from backlash complicates the dynamic analysis of a gear system, the existing models generally either include the nonlinearity but restrict the total degree of freedom of the system so that numerical integration can efciently be used for solution in time domain, or ignore the nonlinearity when the total degree of freedom is large. The solution method used in this study reduces the computational time drastically compared to alternative time integration solution techniques for nonlinear multi-degrees-of-freedom systems. Thus, the mathematical model suggested has the advantages of dealing with large degrees of freedom, which allows us to include dynamic effects of all other

Fig. 8 Comparison of the computational results obtained by NLGRD with the experimental results of Kahraman and Blankenship. Experimental results , NLGRD .

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elements in the system, and to use nite element modeling for shafts, while keeping the nonlinear effects due to backlash that may play a very important role in gear dynamics. The formulation allows including any other nonlinearity into the system, such as clearances at bearings. Moreover, the model presented is not for a xed conguration of a gear-shaft-disk-bearing system, unlike many other models suggested for nonlinear gear dynamic analysis, and the use of nite elements for shafts makes it possible to model various different shaft geometries and non-uniformities. The application of the method suggested is shown with two case studies. In the rst case study, the theoretically obtained dynamic to static load ratios are compared with experimental measurements of Kubo. In the second case study, dynamic transmission errors calculated are compared with the experimental measurements of Kahraman and Blankenship. Generally a good agreement is observed between the results. In the rst case study the theoretical results compare well with the experimental ones, the difference in the numerical values being mainly due to the fact that experimental values are dynamic factors based on tooth stresses, while the theoretical values are the dynamic factors dened as dynamic to static load ratios. In the second case study, the 1 peak values of DTE calculated at resonance and 2 subharmonic resonance frequencies are found to be in very good agreement with the experimental values. It can further be concluded that with the model developed, the jump phenomena observed in experimental studies can be predicted pretty accurately and double solutions can be obtained with upward and downward sweeps. It should be noted that the importance and advantage of the model developed and the solution method suggested can be seen much better for gear systems with various exible elements, so that gear pair cannot accurately be modeled by ignoring the dynamics of the components such as exible shafts and bearings. Furthermore, with the model suggested it is possible to study the interaction and combined inuences of several individual effects considered in the analysis, such as backlash and shaft-bearing exibility. The solution method employed reduces the computational time signicantly making it possible to carry out extensive parametric analyses that could be hardly done with time integration methods when such a large nonlinear nite element model including various effects is used.

v viscous damping factor p spin speed of pinion receptance matrix of the linear part of the system
Subscripts g gear p pinion Superscripts b bearing d rigid disk e nite rotor element Acronyms DF DSLR DTE DYTE NLGRD Dynamic Factor Dynamic to Static Load Ratio Dynamic Transmission Error Dynamic Transmission Error Program See Ref. 34 Nonlinear Geared Rotor Dynamics Program developed in this study

References
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Nomenclature
C F H K M N Np Tg ,Tp X X 1

X 2
e(t) f fp kh p

q yg ,yp
H

damping matrix amplitude of harmonic force vector hysteric damping matrix stiffness matrix mass matrix nonlinear internal force vector number of teeth on pinion torque applied on gears amplitude vector of generalized coordinates amplitude vector of coordinates connected to nonlinear elements amplitude vector of coordinates connected to linear elements loaded static transmission error external force vector nonlinear displacement function average mesh stiffness relative displacement between gear and pinion along the pressure line displacement vector translational displacements of gears along pressure line quasi-linear receptance matrix response dependent dynamic stiffness matrix of the linear part of the system nonlinearity matrix hysteric loss factor

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