Preliminary Evaluation of the Influence of Surface and Tooth Root Damage on the Stress and Strain State of a Planetary Gearbox: An Innovative Hybrid Numerical–Analytical Approach for Further Development of Structural Health Monitoring Models

Concli, Franco; Kolios, Athanasios

doi:10.3390/computation9030038

Cited by 8 publications

(5 citation statements)

References 29 publications

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“…the simulated eigenfrequencies were considered adequate and their estimation results in line with the experimental data. in conclusion, this work can be an effective starting point to setup a monitoring strategy of gearboxes and it can be a powerful tool to predict failures [17].…”

Section: Finite Element Methods (Fem)mentioning

confidence: 84%

A Multibody Dynamic Model for Evaluating the Vibrating Modes of Gear Train Systems

Monteiro¹,

Vidoni²,

Concli³

2021

Int. J. TDI

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A multibody dynAmic model for evAluAting the vibrAting modes of geAr trAin systems r. P. monteiro, r. vidoni & f. concli faculty of science and technology, free university of bozen-bolzano, italy AbstrAct nowadays, the use of gearboxes in the mechanical sector has significantly increased due to the various possible applications and new materials available on the market. moving through each application, from robotics to the automotive sector, the use of gearboxes ensures high efficiency with a compact structure. generally, gearboxes are composed by gears, shafts and bearings, and each of these components can be subjected to failures. therefore, in the analysis of each mechanical component it is central to let the system operate properly. in fact, the presence of a damage can lead to a slight variation of system properties (e.g. stiffness). to design even more reliable gearboxes, it results fundamental to monitor the system's health state and the damage progress. to better understand these phenomena, a numerical study is here presented. A back-to-back gear rig (fixed-axis two-stage test rig) is used as reference. it was developed an effective multibody dynamic model that exploits a combination of two different approaches -the lumped Parameter method (lPm) and the finite element method (fem). in this work, the effect of different operative and loading conditions was studied. in particular, the effect of damages on the eigenfrequencies and on the vibrational spectra was investigated based on numerical simulations. the stiffnesses of the gear train components, used in the lPm, were estimated by means of dedicated fem simulations. the results of the lPm were validated with experimental data acquired on a real healthy back-to-back rig. moreover, the effect of a tooth root damage on the vibrational spectra was analysed. the stiffnesses of the system's components affect considerably the eigenfrequencies. As predicted by the fem simulations, in presence of damage, the stiffness of the teeth varies significantly, affecting the vibrational spectra. therefore, this work can be an effective starting point to setup a monitoring strategy of gearboxes.

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Section: Finite Element Methods (Fem)mentioning

confidence: 84%

A Multibody Dynamic Model for Evaluating the Vibrating Modes of Gear Train Systems

Monteiro¹,

Vidoni²,

Concli³

2021

Int. J. TDI

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“…Furthermore, mesh refinement is also required when the contacts and couplings of the variable rotating components are analyzed in order to obtain convergence with the simulated system. On the other hand, the model presented in this research paper solves, for each contact of the acting components, an additional equation through a relatively coarse grid [52]. This makes the computational effort relatively low, as the number of equations which need to be solved is reduced.…”

Section: Modeling Implementation and Numerical Simulationmentioning

confidence: 99%

“…This, in turn, can be projected onto both the surfaces in this solver stage and the contact pressures that are computed through this procedure, which are not sensitive to grid size. Therefore, additional details are given in [52].…”

Section: Modeling Implementation and Numerical Simulationmentioning

confidence: 99%

A Hybrid Finite Element Method–Analytical Model for Classifying the Effects of Cracks on Gear Train Systems Using Artificial Neural Networks

et al. 2022

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Rotating machinery is fundamental in industry, gearboxes especially. However, failures may occur in their transmission components due to regular usage over long periods of time, even when operations are not intense. To avoid such failures, Structural Health Monitoring (SHM) techniques for damage prediction and in-advance detection can be applied. In this regard, correlations between measured signal variations and damage can be inspected using Artificial Intelligence (AI), which demands large numbers of data for training. Since obtaining signal samples of damaged components experimentally is currently unviable for complex systems due to destructive test costs, model-based numerical approaches are to be explored to solve this problem. To address this issue, this work applied an innovative hybrid Finite Element Method (FEM)–analytical approach, reducing computational effort and increasing performance with respect to traditional FEM. With this methodology, a system can be simulated with accuracy and without geometrical simplifications for healthy and damaged cases. Indeed, considering different positions and dimensions of damages (e.g., cracks) on the tooth roots of gears can offer new ways of damage investigation. As a reference to validate healthy systems and damage cases in terms of eigenfrequencies, a back-to-back test rig was used. Numerical simulations were performed for different cases, resulting in vibrational spectra for systems with no damage, with damage, and with damage of different intensities. The vibration spectra were used as data to train an Artificial Neural Network (ANN) to predict the machine state by Condition Monitoring (CM) and Fault Diagnosis (FD). For predicting the health and the intensity of damage to a system, classification and multi-class classification methods were implemented, respectively. Both sets of classification results presented good prediction agreement.

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“…From this, they have found that gear pitting can cause varying degrees of reduction in the TVMS. Concli et al [5] used a hybrid numerical-analytical approach to study the impact of defects on stress. The results showed that the existence of pitting promoted an instantaneous increase in stress on the rim.…”

Section: Introductionmentioning

confidence: 99%

Effects of Macro-Pitting Fault on Dynamic Characteristics of Planetary Gear Train Considering Surface Roughness

Li,

Xiong,

et al. 2023

Actuators

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The planetary gearbox plays a vital role in a wide range of mechanical power transmission systems, including high-speed trains, wind turbines, vehicles, and aircraft. At the same time, the planetary gear train inside the gearbox is regarded as the most susceptible to failure in the entire transmission system. To analyze the influence of surface roughness on the dynamic characteristics of the planetary gear train, a dynamic modeling method based on fractal theory is proposed. Firstly, the tooth surface contact model was established based on the W-M fractal function, and the time-varying mesh stiffness (TVMS) of the planetary gear train was calculated under healthy and tooth macro-pitting. Then, the lumped-parameter method is introduced to construct a planetary gear train translation-torsion dynamic model that comprehensively considers TVMS and tooth backlash. The vibration acceleration signals of the planetary gear train under different macro-pitting states and surface roughness are simulated and calculated, allowing a quantificative analysis of the influence of surface roughness on system vibration response. Finally, the correctness of the model for the planetary gear train is verified by experiments. The results show that compared with the planetary gear train modeling method based on Hertz contact theory, the root mean squared error of the vibration signal of this work under a macro-pitting fault state is reduced by 8.7%, further improving the reliability of the model.

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Preliminary Evaluation of the Influence of Surface and Tooth Root Damage on the Stress and Strain State of a Planetary Gearbox: An Innovative Hybrid Numerical–Analytical Approach for Further Development of Structural Health Monitoring Models

Cited by 8 publications

References 29 publications

A Multibody Dynamic Model for Evaluating the Vibrating Modes of Gear Train Systems

A Multibody Dynamic Model for Evaluating the Vibrating Modes of Gear Train Systems

A Hybrid Finite Element Method–Analytical Model for Classifying the Effects of Cracks on Gear Train Systems Using Artificial Neural Networks

Effects of Macro-Pitting Fault on Dynamic Characteristics of Planetary Gear Train Considering Surface Roughness

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