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Nonlinear dynamic response of a multi-degree of freedom gear system dynamic model coupled with tooth surface characters: a case study on coal cutters

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Abstract

The operation environment of coal cutter gearboxes can be significantly harsher than that of gear systems for general applications. The influence factors, including low speed, heavy load, high environmental temperature, high humidity, heavy dust, accelerate the gears failure rate. It is therefore imperative to investigate gear failure mechanisms by developing reliable gear dynamic models. Although literature review indicates that many nonlinear mathematical models have been built to analyze the gear dynamics, very limited works have addressed the effect of the tooth tribological characteristics on the gear dynamic response for coal cutters. For this reason, a multi-degree of freedom (MDOF) gear nonlinear model, which considers gear tooth characters, is presented in this work. In addition to the nonlinear factors of the gear meshing, the nonlinear effect of the support bearings was considered in this new model. In order to reliably estimate the gear backlash and bearing clearance, the fractal theory was employed to calculate the nonlinear backlash and clearance from the tribological aspect. Numerical simulations were used to calculate the gear dynamics of the presented model, and the results were validated using experimental data. The performance of the fractal expression estimation for the backlash and clearance was compared with that of existing fixed value and normal distribution methods. The comparison results demonstrate that the proposed MDOF gear model with the fractal estimation method provides more reliable dynamic response than that of the other two methods and the simulation result obtained with suitable fractal dimension was consistent with the experimental data. Hence, the presented new MDOF gear model can correctly describe the dynamic behavior of the coal cutter gear systems and can be used as a feasible and reliable tool for gear fault mechanism investigation.

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Acknowledgments

This research was funded by the National Natural Sciences Foundation of China (NSFC) (No. 51505475), the Fundamental Research Funds for the Central Universities (No. 2015XKMS018) and the Priority Academic Program Development of Jiangsu Higher Education Institutions.

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Authors and Affiliations

  1. School of Mechatronic Engineering, Jiangsu Key Laboratory of Mine Mechanical and Electrical Equipment, China University of Mining and Technology, Xuzhou, 221110, China

    Zhixiong Li

  2. School of Mechanical and Manufacturing Engineering, The University of New South Wales, Sydney, NSW, 2052, Australia

    Zhixiong Li & Z. Peng

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  1. Zhixiong Li
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  2. Z. Peng
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Correspondence to Zhixiong Li.

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Li, Z., Peng, Z. Nonlinear dynamic response of a multi-degree of freedom gear system dynamic model coupled with tooth surface characters: a case study on coal cutters. Nonlinear Dyn 84, 271–286 (2016). https://doi.org/10.1007/s11071-015-2475-5

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  • DOI: https://doi.org/10.1007/s11071-015-2475-5

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