Meshing Characteristics Analysis of Spiral Bevel Gear Pairs with Different Crack Types

doi:10.12068/j.issn.1005-3026.2024.08.005

Abstract

Abstract:

Under the working conditions of heavy load and alternating load， spiral bevel gears are prone to tooth root cracks， which lead to tooth fractures. It is necessary to clarify the influence mechanism of cracks on meshing characteristics and provide theoretical basis for fault diagnosis. The finite element model of bevel gear pairs is constructed， and the static contact simulation analysis is carried out by ANSYS software. The fault models of various crack types are set up by the method of unit node replacement， and the influence of cracks on the meshing characteristics of spiral bevel gear pairs is discussed. The results show that when the contact ellipse of gear teeth moves to the crack area of gear teeth， the meshing stiffness gradually decreases with the increase of the severity of the crack， and the maximum reduction of stiffness under the condition of plane crack， space crack and broken teeth is 27.58%， 14.12% and 32.82% respectively. The contact ellipse position， crack position and depth of gear meshing will make the contact stress of tooth surface and the bending stress of tooth root have different increasing and decreasing trends.

Key words: spiral bevel gear（SBG）, tooth crack type, fault parameter, meshing stiffness, contact characteristics, tooth contact analysis（TCA）

CLC Number:

TH 132.422

Han-sheng SONG, Hui MA, Zi-meng LIU, Wen-kang HUANG. Meshing Characteristics Analysis of Spiral Bevel Gear Pairs with Different Crack Types[J]. Journal of Northeastern University(Natural Science), 2024, 45(8): 1096-1106.

Figures/Tables 21

Fig. 1 Coordinate system model of spiral bevel gear machining

Fig. 2 Tool coordinate system model of spiral bevel gear

Fig. 3 Tooth surface of gear and pinion

Fig. 4 Finite element model of bevel gear

Fig. 5 Comparison of meshing stiffness in the good condition

Fig. 6 Schematic of crack types

Table 1 Parameters of plane crack working conditions

工况	弧长
工况	齿宽方向	齿厚方向
工况1	W/3	P/6
工况2	W/3	P/3
工况3	W/3	P/2
工况4	W/3	2P/3
工况5	W/3	5P/6
工况6	2W/3	P/6
工况7	2W/3	P/3
工况8	2W/3	P/2
工况9	2W/3	2P/3
工况10	2W/3	5P/6
工况11	W	P/6
工况12	W	P/3
工况13	W	P/2
工况14	W	2P/3
工况15	W	5P/6

Table 2 Parameters of space crack working conditions

工况	角度方向角/（°）	齿厚方向弧长
工况1	α₁	S/6
工况2	α₁	S/3
工况3	α₁	S/2
工况4	α₁	2S/3
工况5	α₁	5S/6
工况6	α₂	S/6
工况7	α₂	S/3
工况8	α₂	S/2
工况9	α₂	2S/3
工况10	α₂	5S/6
工况11	α₃	S/6
工况12	α₃	S/3
工况13	α₃	S/2
工况14	α₃	2S/3
工况15	α₃	5S/6
工况16	α₁	断齿
工况17	α₂	断齿
工况18	α₃	断齿

Fig. 7 Unit separation state diagram

Fig. 8 Solution process of static meshing mechanical model of bevel gear with crack fault

Fig. 9 Equivalent stress nephogram of gear teeth under the good and plane crack working conditions

Fig. 10 Equivalent stress nephogram of gear teeth under the good and spatial crack working conditions

Fig. 11 Equivalent stress nephogram of gear teeth under the broken tooth working conditions

Fig. 12 Gear tooth meshing stiffness under the good

Fig. 13 Gear tooth meshing stiffness under the good and different space crack working conditions

Fig. 14 Gear tooth meshing stiffness under the good and different broken tooth working conditions

Fig. 15 Stress extraction position of tooth surface and tooth root

Fig. 16 Contact stress of tooth surface under plane crack working conditions 1~5

Fig. 17 Bending stress at tooth root of every position under plane crack working conditions 1~5

Fig. 18 Contact stress of tooth surface under spatial crack working conditions 1~5

Fig. 19 Bending stress at the tooth root of every position under spatial crack working conditions 1~5

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