DESIGN OF TOOTH FLANK MODIFICATIONS IN TRANSMISSION SYSTEMS CONSIDERING DYNAMIC MISALIGNMENTS

Current challenges in gear design, such as higher speeds and increasing power density, are leading to the increasing use of power-split and high-ratio transmission systems. These requirements can be achieved with planetary and stepped planetary gear systems. However, the power split of these gearbox types results in kinematic overdetermination and a pronounced misalignment behavior. In this report, a method is developed for the design of tooth flank modifications in transmission systems, taking into account dynamic misalignments caused by manufacturing or assembly deviations. For this purpose, the simulation of the dynamic operational behavior of transmission systems with assembly or manufacturing deviations in the dynamic multi-body simulation (MBS) is described. The focus is on the modeling of the tooth contact with the force element GEARFORCE6D developed for the MBS software DASSAULT SYSTEMES SIMPACK. In the following, a novel combination of the MBS with the quasi-static tooth contact analysis (TCA) is presented. Here, the misalignment and load time histories simulated in the MBS are used for the detailed calculation of the gear meshes. With the combination of the MBS and the TCA, a significant reduction of the calculation time for the variation of tooth flank modifications is possible. The developed method is used for the design of tooth flank modifications of a stepped planetary gearbox considering a misalignment of the planet carrier. The optimized tooth flank modifications show that a significant improvement in operational behavior can be achieved by considering the dynamic misalignment in the design. The load-related misalignment of the gear components has a high influence on the dynamic operational behavior.