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ABSTRACT NON-LINEAR MATHEMATICAL MODELING OF GEAR-ROTOR-BEARING SYSTEMS INCLUDING BEARING CLEARANCE G&Uuml / RKAN, Niyazi Ersan M.S. Department of Mechanical Engineering Supervisor: Prof. Dr. H. Nevzat &Ouml / ZG&Uuml / VEN November 2005, 130 pages In this study, a non-linear mathematical model of gear-rotor systems which consists of elastic shafts on elastic bearings with clearance and coupled by a non-linear gear mesh interface is developed. The mathematical model and the software (NLGRD 2.0) developed in a previous study is extended to include the non-linear effects due to bearing clearances by using non-linear bearing models. The model developed combines the versatility of using finite element method and the rigorous treatment of non-linear effect of backlash and bearing clearances on the dynamics of the system. The software uses the output of Load Distribution Program (LDP), which computes loaded static transmission error and mesh compliance for the contact points of a typical mesh cycle, as input. Although non-varying mesh compliance is assumed in the model, the excitation effect of time varying mesh stiffness is indirectly included through the loaded static transmission error, which is taken as a displacement input into the system. Previous computer program which was written in Fortran 77 is rewritten by using MatLAB 7.0 and named as NLGRD (Non-Linear Geared Rotor Dynamics) Version 3.0. The program is highly flexible and open to further developments. The program calculates dynamic to static load ratio, dynamic transmission error, forces and displacements at bearings. The mathematical model suggested and the code (NLGRD version 3.0) are validated by comparing the numerical results obtained from the model suggested with experimental data available in literature. The results are also compared with those of previously developed non-linear models. The effects of different system parameters such as bearing stiffness, bearing clearance and backlash on the gears are investigated. The emphasis is placed on the interaction of clearances in bearings with other system parameters.

La nécessité de simuler des systèmes complexes et multi-physiques est de plus en plus courante dans l’industrie, en particulier avec l’avènement de la conception mécatronique. Ce phénomène couplé à la pression économique poussant les industriels dans la voie de l’optimisation de leurs produits conduit à une augmentation forte des temps de simulation que les progrès techniques ne parviennent pas à compenser. Les travaux menés lors de cette thèse ont permis de proposer une approche hybride analytique/éléments finis pour la simulation temporelle de la dynamique des transmissions par engrenages en présence de non-linéarités de contact. Couplée à une réduction des modèles éléments finis, cette approche permet la résolution rapide de la dynamique d’un réducteur et offre ainsi la possibilité d’intégrer le réducteur comme composant d’un système complexe tel qu’un système mécatronique. La résolution de la dynamique du réducteur peut être menée en parallèle des autres physiques en prenant en compte des couplages forts. L’optimisation d’un tel système est abordée sur un exemple pour clore cette étude. / The need to simulate complex and multi-physics systems is increasingly common in the industry, especially with the advent of mechatronic design. This coupled with economic pressure pushing the industry towards optimizing their products led to a strong increase in simulation time that technological advances can not compensate. An hybrid method analytical/finite element has been developed for the time domain simulation of gear transmissions involving contact non-linearities. Coupled with a reduction of finite element models, this approach allows fast resolution of the dynamics of a gearbox. Consequently, it is possible to integrate a gearbox as a part of a more complex mechatronic system. All physical phenomena involved in such a complex product are solved at the same time allowing strong coupling to be considered. The optimization of such a system is discussed with an example to conclude this study.

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