Non-linear dynamic analysis of geared systems, part 2

A good understanding of the steady state dynamic behavior of a geared system is required in order to design reliable and quiet transmissions. This study focuses on a system containing a spur gear pair with backlash and periodically time-varying mesh stiffness, and rolling element bearings with clearance type non-linearities. A dynamic finite element model of the linear time-invariant (LTI) system is developed. Effects of several system parameters, such as torsional and transverse flexibilities of the shafts and prime mover/load inertias, on free and force vibration characteristics are investigated. Several reduced order LTI models are developed and validated by comparing their eigen solution with the finite element model results. Several key system parameters such as mean load and damping ratio are identified and their effects on the non-linear frequency response are evaluated quantitatively. Other fundamental issues such as the dynamic coupling between non-linear modes, dynamic interactions between component non-linearities and time-varying mesh stiffness, and the existence of subharmonic and chaotic solutions including routes to chaos have also been examined in depth

Effects of bearing clearance on the chatter stability of milling process

In the present study, the influences of the bearing clearance, which is a common fault for machines, to the chatter stability of milling process are examined by using numerical simulation method. The results reveal that the presence of bearing clearance could make the milling process easier to enter the status of chatter instability and can shift the chatter frequency. In addition, the spectra analysis to vibration signals obtained under the instable milling processes show that the presence of bearing clearance could introduce more frequency components to the vibration responses but, however, under both the stable and instable milling processes, the generated frequency components will not violate the ideal spectra structures of the vibration responses of the milling process, which are usually characterized by the tooth passing frequency and its associated higher harmonics for the stable milling process and by the complex coupling of the tooth passing frequency and the chatter frequency for the instable milling process. This implies that, even under the case with bearing clearance fault, the stability of the milling process can still be determined by viewing the frequency spectra of the vibration responses. Moreover, the phenomena of the chatter frequency shift and the generation of more components provide potential ways to detect the bearing clearance in machines. (C) 2010 Elsevier Ltd. All rights reserved

Surface roughness variation of thin wall milling, related to modal interactions

High-speed milling operations of thin walls are often limited by the so-called regenerative effect that causes poor surface finish. The aim of this paper is to examine the link between chatter instability and surface roughness evolution for thin wall milling. Firstly, the linear stability lobes theory for the thin wall milling optimisation was used. Then, in order to consider the modal interactions, an explicit numerical model was developed. The resulting nonlinear system of delay differential equations is solved by numerical integration. The model takes into account the coupling mode, the modal shape, the fact that the tool may leave the cut and the ploughing effect. Dedicated experiments are carried out in order to confirm this modelling. This paper presents surface roughness and chatter frequency measurements. The stability lobes are validated by thin wall milling. Finally, the modal behaviour and the mode coupling give a new interpretation of the complex surface finish deterioration often observed during thin wall milling

Finite element for rotor/stator interactive forces in general engine dynamic simulation. Part 1: Development of bearing damper element

A general purpose squeeze-film damper interactive force element was developed, coded into a software package (module) and debugged. This software package was applied to nonliner dynamic analyses of some simple rotor systems. Results for pressure distributions show that the long bearing (end sealed) is a stronger bearing as compared to the short bearing as expected. Results of the nonlinear dynamic analysis, using a four degree of freedom simulation model, showed that the orbit of the rotating shaft increases nonlinearity to fill the bearing clearance as the unbalanced weight increases

Early Failure Detection and Diagnostics of High Speed Self Aligning Journal Bearing

Because of their high load carrying capacity and low cost, journal bearings are widely used to support the rotor of industrial machinery with high loads, such as steam turbines, centrifugal compressors and pumps. However, sudden catastrophic failure journal bearings can result in huge economic loss and high safety problems. It is necessary to develop effective condition monitoring technologies to detect and diagnose the failures at early stage and avoid such catastrophic failure. Previous researchers have studied the low frequency vibration characteristics as well as the high frequency vibration and acoustics emission for the early detection of journal bearing failure. However, these studies give relatively little information to the vibro-acoustic characteristics of high speed self aligning journal bearings. This paper focuses on the condition monitoring of high speed self aligning journal bearings through vibro-acoustic analysis

Control of rotordynamic instability in a typical gas turbine's power system

The effect of rotor internal friction on the system's stability was studied when operated above the first critical speed. This internal friction is commonly caused by sliding press fits or sliding splines. Under conditions of high speed and low bearing damping, these systems will occassionally whirl at a frequency less than the shaft's rotational speed. This subsynchronous precession is a self excited phenomenon and stress reversals are created. This phenomenon was observed during engine testing. The reduction of spline friction and/or the inclusion of squeeze film damping have controlled the instability. Case history and the detail design of the squeeze film dampers is discussed

A microgravity isolation mount

The design and preliminary testing of a system for isolating microgravity sensitive payloads from spacecraft vibrational and impulsive disturbances is discussed. The Microgravity Isolation Mount (MGIM) concept consists of a platform which floats almost freely within a limited volume inside the spacecraft, but which is constrained to follow the spacecraft in the long term by means of very weak springs. The springs are realized magnetically and form part of a six degree of freedom active magnetic suspension system. The latter operates without any physical contact between the spacecraft and the platform itself. Power and data transfer is also performed by contactless means. Specifications are given for the expected level of input disturbances and the tolerable level of platform acceleration. The structural configuration of the mount is discussed and the design of the principal elements, i.e., actuators, sensors, control loops and power/data transfer devices are described. Finally, the construction of a hardware model that is being used to verify the predicted performance of the MGIM is described

On the modelling of spur and helical gear dynamic behaviour

This chapter is aimed at introducing the fundamentals of spur and helical gear dynamics. Using three-dimensional lumped models and a thin-slice approach for mesh elasticity, the general equations of motion for single-stage spur or helical gears are presented. Some particular cases including the classic one degree-of-freedom model are examined in order to introduce and illustrate the basic phenomena. The interest of the concept of transmission errors is analysed and a number of practical considerations are deduced. Emphasis is deliberately placed on analytical results which, although approximate, allow a clearer understanding of gear dynamics than that provided by extensive numerical simulations. Some extensions towards continuous models are presented