Hindawi

Journal of Control Science and Engineering

Volume 2017, Article ID 3169172, 8 pages
https://doi.org/10.1155/2017/3169172

Research Article
Tooth Fracture Detection in Spiral Bevel Gears System by
Harmonic Response Based on Finite Element Method

Yuan Chen,1,2 Rupeng Zhu,1 Guanghu Jin,1 and Yeping Xiong2

1
College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
2
Engineering and Environment, University of Southampton, Boldrewood Innovation Campus, Southampton SO16 7QF, UK

Correspondence should be addressed to Rupeng Zhu; [email protected]

Received 11 August 2017; Revised 11 October 2017; Accepted 19 October 2017; Published 3 December 2017

Academic Editor: Zhixing Cao

Copyright © 2017 Yuan Chen et al. This is an open access article distributed under the Creative Commons Attribution License,
which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

Spiral bevel gears occupy several advantages such as high contact ratio, strong carrying capacity, and smooth operation, which
become one of the most widely used components in high-speed stage of the aeronautical transmission system. Its dynamic
characteristics are addressed by many scholars. However, spiral bevel gears, especially tooth fracture occurrence and monitoring,
are not to be investigated, according to the limited published issues. Therefore, this paper establishes a three-dimensional model
and finite element model of the Gleason spiral bevel gear pair. The model considers the effect of tooth root fracture on the system
due to fatigue. Finite element method is used to compute the mesh generation, set the boundary condition, and carry out the
dynamic load. The harmonic response spectra of the base under tooth fracture are calculated and the influence of main parameters
on monitoring failure is investigated as well. The results show that the change of torque affects insignificantly the determination of
whether or not the system has tooth fracture. The intermediate frequency interval (200 Hz–1000 Hz) is the best interval to judge
tooth fracture occurrence. The best fault test region is located in the working area where the system is going through meshing. The
simulation calculation provides a theoretical reference for spiral bevel gear system test and fault diagnosis.

1. Introduction transmission errors for reduction of noise and vibration and

found severe contact stresses areas to increase the endurance
Spiral bevel gears are one of the most important components of the gear drives; the proposed results were proved by the
of the aeronautical transmission system. Due to the harsh manufacturing and test of prototypes. Sheveleva et al. [7, 8]
working environment, failure occurs sometimes, and the developed a modified computer program for tooth contact
most common situation is resonance failure. The failure of the analysis (TCA) for the most general case and provided
spiral bevel gear transmission system often leads to serious computer codes for contact path, bearing contact, and contact
accidents; therefore, accurate detection, the positioning of pressure distribution. Simon [9] presented computer aided
the fault, and eliminating hidden danger have very important tooth contact analysis in mismatched spiral bevel gears and
significance in improving the operating efficiency of the gear discussed the influence of relative position errors of meshing
system. pinion on tooth contact.
Most studies were related to spiral bevel gear modeling About spiral bevel gear fault detection, Zakrajsek et al.
and tooth contact analysis (TCA); Tsai and Chin [1] devel- [10] applied a variety of gear fault detection techniques to
oped mathematical modeling of the tooth surface geometry investigate the growth and propagation of the fault; the
for bevel gear pairs based on the basic gearing kinematics and relationship between the system running time and pinion
involute geometry along with the tangent planes geometry. damage was specified as well. Dempsey et al. [11] developed
Litvin et al. [2–6] proposed an integrated computerized the diagnostic tool by collecting vibration and oil debris
approach for spiral bevel gear drives and simulated mesh data from fatigue tests performed in Glenn spiral bevel
and contact stress analysis; they reduced the magnitude of gear fatigue rigs. Decker and Lewicki [12] discussed the
2 Journal of Control Science and Engineering

Mean cone circle

Outer cone circle m

Sk
jk
j0 S0
O O1

Virtual cutting gear

Inner cone

L1

Figure 1: Pitch surface unfolded map.

damage detection effectiveness of the different metrics and the spiral bevel gear. By adding the auxiliary involute to the
a comparison of effects of different accelerometer locations tooth line equation, the accuracy of the tooth surface could
by spiral bevel pinion running test. Ural et al. [13] predicted be increased.
the crack shape and fatigue life for a spiral bevel pinion In the spherical coordinate system, the spherical involute
gear by using computational fracture mechanics, which was equation on one side of outer space width is
based on linear elastic fracture mechanics theories combined
with finite element method. However, the detection in the 𝑟=𝑅
frequency domain and the influence of excitation were not
provided in these papers. 𝜃 = 𝛿𝑓 + 𝑡 (𝛿𝑎 − 𝛿𝑓 )
(1)
In the area of spiral gear dynamics analysis, Li and Hu
[14] analyzed the axial–lateral–torsional coupled spiral bevel arccos (cos 𝜃/ cos 𝛿𝑏 ) tan 𝛿𝑏
𝜑= − arccos ( ),
geared system theoretically and the dynamic behavior of the sin 𝛿𝑏 tan 𝜃
system was investigated by numerical method. Yinong et al.
[15] studied the effect of the asymmetric mesh stiffness on the where 𝛿𝑏 is base angle; 𝛿𝑓 is root angle; 𝛿𝑎 is tip angle; 𝑅 is
8-DOF spiral bevel gear transmission system. Feng and Song sphere radius, that is, outer cone distance.
[16] investigated the effects of the dynamic meshing force and The spherical involute equation on the other side of outer
dynamic transmission error. space width is
Therefore, through system vibration signal to determine 𝑟=𝑅
the occurrence of tooth fracture, thus eliminating the fault,
is a meaningful work. In this paper, a pair of Gleason 𝜃 = 𝛿𝑓 + 𝑡 (𝛿𝑎 − 𝛿𝑓 ) ;
spiral bevel gears is mathematically modeled and a three-
dimensional solid model is generated as well. Finite element arccos (cos 𝜃/ cos 𝛿𝑏 ) tan 𝛿𝑏 (2)
method is applied to analyze the harmonic response of 𝜑= − arccos ( )
sin 𝛿𝑏 tan 𝜃
the system; deformation amplitude and phase of the base
are calculated. Therefore some tooth fracture features and 360
main parameters’ influences are analyzed to assist the fault −( − 𝜙𝑏 )
𝑧
recognition.
here, 𝑧 is tooth number; 𝜑𝑏 is tooth thickness base angle.
2. System Modeling When spiral bevel gears are in cutting processing, tooth
pitch surface unfolded drawing is shown in Figure 1.
2.1. Three-Dimensional Precise Solid Modeling. Typical spiral The distance between cutting tool circle 𝑂1 and cone
bevel gears applied in aeronautical transmission system are circle 𝑂 is depicted as
manufactured by Gleason face hobbing process [17]. The
tooth profile of the spiral bevel gear is a spherical involute, 𝐿 1 = √𝑅𝑚 2 + 𝑅𝑑 2 − 2𝑅𝑚 𝑅𝑑 sin 𝛽𝑚 , (3)
and its tooth profile is circular, and the tooth surface is a
complex three-dimensional surface. Therefore, the method of where 𝛽𝑚 is mean spiral angle; 𝑅𝑚 is mean cone distance; 𝑅𝑑
modeling the cylindrical gear tooth profile is not suitable for is the radius of cutting tool.
Journal of Control Science and Engineering 3

(a) Healthy model (b) Tooth fracture model

Figure 2: Spiral bevel gear assembly model.

In circle 𝑂1 , offset angle 𝑆0 of outer cone circle and 𝑆𝑘 of Table 1: System parameters.
inner cone circle are
Active gear Driven gear
𝐿 + 𝑅𝑑 2 − 𝑅2 Modulus 6
𝑆0 = 180 − arccos 1
2𝐿 1 𝑅𝑑 Pressure angle (∘ ) 20
(4) Tooth number 15 46
𝐿 + 𝑅𝑑 2 − (𝑅 − 𝐵)2
𝑆𝑘 = 180 − arccos 1 ; Tooth width (m) 0.44 0.44
2𝐿 1 𝑅𝑑 Shaft angle Σ(∘ ) 90
Mean spiral angle (∘ ) 35
here, 𝐵 is tooth thickness.
In circle 𝑂, offset angle 𝑗0 of outer cone circle and 𝑗𝑘 of
inner cone circle are is based on these tooth surfaces. Finally, with the Boolean
𝑅𝑑 sin 𝑆0 subtraction calculation of the solids, the parametric modeling
𝑗0 = arctan of the spiral bevel gear could be successfully achieved, which
𝐿 1 + 𝑅𝑑 cos 𝑆0 verifies the correctness of the design method [18].
(5)
𝑅𝑑 sin 𝑆𝑘 In addition, due to long-term operation in the high-speed
𝑗𝑘 = arctan . circumstance, tooth root is prone to fatigue fracture. This
𝐿 1 + 𝑅𝑑 cos 𝑆𝑘
paper simulates the fractured tooth and completes the healthy
According to the spherical geometrical relationship, and fracture spiral bevel gear assembly model, as shown in
spherical angle 𝑞 corresponding to plane angle 𝑗 could be Figure 2; main parameters are listed in Table 1.

𝑗0 2.2. Finite Element Meshing and Pretreatment Process. The

𝑞0 = geometric model in CATIA is introduced into ANSYS work-
sin 𝛿
(6) bench 18.1, so finite element analysis model is obtained. As
𝑗
𝑞𝑘 = 𝑘 ; friction contact analysis is a nonlinear problem, in order
sin 𝛿 to save the computing resources and improve calculation
accuracy, hexahedral meshing method is applied for calcula-
here, 𝛿 is reference cone angle.
tion, and then the grid is refined in contact areas. The grid
Thus, 𝑞0𝑘 = 𝑞𝑘 − 𝑞0 , that is, the rotation angle between
size of the noncontact region of this model is defined as
outer cone and inner cone in the spherical coordinate system.
5 mm, and the contact area is defined as 1 mm, which ensures
The spherical involute equation on one side of inner space
the rationality of the mesh and the maximum efficiency. At
width could be derived by substituting 𝑟 to (R-B) and adding
the same time, in order to ensure the convergence of the
the value of 𝜑 to 𝑞0𝑘 in (1). Similarly, involute equation on the
calculation results, the meshing model is firstly calculated,
other side of inner space width could be deduced as well.
and then the mesh size of the contact area is gradually
In order to improve the accuracy of the three-
reduced. If the difference between calculation results is
dimensional model, in this paper, a number of equally
small after multiple attempts, the result is convergent and
spaced auxiliary spherical involute lines are inserted in the
acceptable. Figure 3 shows the meshing model of spiral bevel
direction of the tooth line. Substitute (R-B) to (R-0.1nB) in
gear pair; the results tend to converge when the number
(1) and (4), and 𝑛 is followed by 1, 2, 3 . . . 9 . . ., then involute
of nodes is 151443 and the number of elements is 47982 in
equation could be rederived.
healthy model; the number of nodes is 151749 and the number
Based on the above-mentioned involute equation, key
of elements is 47728 in tooth fracture model.
points of the curve are established by “law command” in
After mesh is complete, the model is processing multiple
CATIA. Then “spline command” is applied to connect these
settings, that is, pretreatment process:
key points for the tooth profile involute curve, and “multisec-
tion surface command” is used to generate the tooth surface. (1) Material definition: the model is set according to
Moreover, tooth space is modeled by “split command,” which steel properties, the active and driven gears belong to
4 Journal of Control Science and Engineering

(a) Healthy model (b) Tooth fracture model

(c) Contact area of healthy model (d) Contact area of tooth fracture model

Figure 3: Spiral bevel gear meshing.

the same material, Young’s modulus is 2.1 × 1011 Pa, where [𝑀], [𝐶], and [𝐾] are the mass matrix, damp-
Poisson’s ratio is 0.3, and the density is 7850 kg/m3 . ing matrix, and stiffness matrix of the system. Matrix
[𝐹] is external excitation and is equal to 𝐹0 cos(𝜔𝑡).
(2) Contact definition: the calculation of the spiral
bevel gear pair is surface-to-surface contact problem The time-varying meshing stiffness, meshing line
displacement, and dynamic meshing force can be
between the elastomers. It is of great importance to
regarded as periodic format and can be expanded in
select contact surface and target surface; the inap-
Fourier series under fundamental meshing frequency.
propriate selection will lead to excessive penetration,
In this paper, dynamic meshing force is simulated
affecting the accuracy of the solution. In general, as the excitation load, the torque is loaded in the
when the convex and concave surfaces contact, the sinusoidal form, the sweep frequency is set from 0
concave surface should be set as the target surface, so to 2000 Hz, initial phase angle is 0∘ , and solution
the spiral bevel gear outer tooth surface is defined as intervals are 100.
the target surface. In addition, the amount of pene-
(5) Boundary conditions and load setting: degree of free-
tration between the two contact surfaces depends on
dom (DOF) is released only in rotational direction,
the normal contact stiffness. If the normal contact
and the value of torque is 1200 N⋅m, which is gradually
stiffness is too large, it will increase solution iteration
applied on the active gear.
number, which may lead to nonconvergence; if the
normal contact stiffness is too small, the penetra-
tion between nodes could be too large, resulting in
3. Fault Diagnosis Analysis
model instability. Based on the above analysis, this 3.1. Tooth Fracture Detection. The system is solved by the
paper firstly uses the small normal contact stiffness augmented Lagrangian method in ANSYS and the first six
coefficient and then gradually increases until analysis natural frequencies of the system are obtained, as shown in
results deviation is so small. The results show that the Table 2. As illustrated in the table, the natural frequency of the
best normal contact stiffness coefficient is 1.0 when tooth fracture model decreases in each order; the frequency
the normal contact stiffness coefficient is set from deviation of the fourth and sixth order is relatively large.
0.001, 0.01, 0.1, 1.0, and 1.1. The base of the driven gear is the optimum position
for deformation vibration detection sensor and acceleration
(3) Rotational pair definition: the inner surfaces of the vibration detection sensor so that the base is also set in
gears are set as reference surfaces, and then the response to the output in finite element method. Figure 4
rotational centers of reference surfaces are created. shows the calculated deformation and acceleration harmonic
Finally, a pair of rotational gears is defined. response maps.
(4) Solver definition: the general equation for harmonic Here, in order to separate ideal monitoring frequency,
response analysis is three frequency intervals are defined to describe the sweep
frequency, that is, low frequency interval (below than 200
̈ + [𝐶] {𝑋}
̇ + [𝐾] {𝑋} = {𝐹} , Hz), intermediate frequency interval (200 Hz to 1000 Hz),
[𝑀] {𝑋} (7) and high frequency interval (greater than 1000 Hz) [19].
Journal of Control Science and Engineering 5

Table 2: Natural frequency.

Order Healthy tooth model frequency (Hz) Fracture tooth model frequency (Hz) Deviation (Hz)
(1) 18.4 12.0 6.4
(2) 168.0 140.8 27.2
(3) 206.5 147.3 59.2
(4) 678.1 571.6 106.5
(5) 1061.2 1042.4 18.8
(6) 1543 1367.3 175.7

0.015 180
Healthy Healthy
Crack Crack
160

140
Deformation amplitude (m)

0.01 120

Phase angle (∘ )
100

80

0.005 60

40

20

0 0
0 200 400 600 800 1000 1200 1400 1600 1800 2000 0 200 400 600 800 1000 1200 1400 1600 1800 2000
Frequency (Hz) Frequency (Hz)
(a) Deformation amplitude (b) Deformation phase angle
4
×10
12 180
Healthy Healthy
Crack Crack
160
10
140

8 120
Acceleration (m/Ｍ2 )

Phase angle (∘ )

100
6
80

4 60

40
2
20

0 0
0 200 400 600 800 1000 1200 1400 1600 1800 2000 0 200 400 600 800 1000 1200 1400 1600 1800 2000
Frequency (Hz) Frequency (Hz)
(c) Acceleration amplitude (d) Acceleration phase angle

Figure 4: Harmonic response spectrum of spiral bevel gear.

In low frequency interval, the tooth fracture model has acceleration amplitude spectrum, while the peak value of
a significant peak in the deformation amplitude spectrum, healthy tooth model is very obvious. And there is no other
while the healthy tooth model has a valley in this interval. interference signal in this interval and adjacent interval, so
However, in the acceleration amplitude spectrum, the peaks it can be effective in monitoring frequency interval for tooth
of two models are equivalent. fracture detection.
In intermediate frequency interval, the tooth fracture In high frequency interval, the acceleration amplitude
model does not show an obvious peak in deformation and spectrum is peaked at about 1050 Hz in fracture model, and
6 Journal of Control Science and Engineering

0.014 180

0.012 160

140
Deformation amplitude (m)

0.01
120

Phase angle (∘ )
0.008 100

0.006 80

60
0.004
40
0.002
20

0 0
0 200 400 600 800 1000 1200 1400 1600 1800 2000 0 200 400 600 800 1000 1200 1400 1600 1800 2000
Frequency (Hz) Frequency (Hz)
1200 N·m 900 N·m 800 N·m
1100 N·m 800 N·m
1000 N·m
(a) Deformation amplitude (b) Deformation phase angle

Figure 5: Influence of torque on harmonic response of spiral bevel gear.

the peak of healthy tooth model is four times that of the loaded without changing the other pretreatment process, so
fracture model. excitation’s influence on tooth fracture detection could be
Compared with Figures 4(a) and 4(c), several peaks of the obtained. The harmonic response of each load is calculated,
fracture are in the vicinity of the sidebands of the healthy, respectively, and the result is shown in Figure 5. It can be
and for each corresponding peak, the fracture is less than the seen from Figure 5(a) that the torque magnitude has a great
healthy; as is shown in Figure 4(a), the peaks also gradually influence on the peak value in low frequency interval, and
reduce with the increase of the frequency, so high frequency the peak value increases with the torque obviously. However,
interval cannot easily detect fracture tooth signal. However, the torque magnitude has little impact on the intermediate
acceleration signal is mainly concentrated in intermediate frequency and high frequency intervals. As can be seen from
and high frequency intervals. Figure 5(b), the phase spectrum does not change with the
Compared with Figures 4(b) and 4(d), it can be seen increase of torque; that is, torque does not affect the harmonic
that deformation phase spectrum and acceleration phase response phase. This conclusion successfully verifies the
spectrum are corresponding to the contrary. And during the experimental test in [12].
sweep process, the phase will be reversed between 0∘ and
180∘ in different frequencies. In low frequency interval, the 3.3. Influence of Measuring Point Position on Harmonic
healthy and the fracture coincide and separate from each Response of Spiral Bevel Gear. In order to improve the accu-
other quickly, so it is difficult to judge whether the tooth is racy of the test, the influence of the measuring point position
fractured. The phase mutation inversion is most pronounced on the harmonic response of the spiral bevel gear system
at about 600 Hz in the intermediate interval, and it is depicted is studied. The responses of the different measuring points
in both the deformation and acceleration phase spectra. In are calculated without changing the other pretreatment, so
addition, phase reversal at 1400 Hz in high frequency interval the best monitoring area could be found. The position of
is also relatively obvious. the test points is shown in Figure 6, where point A is
In brief, low frequency, intermediate frequency, and high the measuring point near the working area. The harmonic
frequency interval sections all have tooth fracture charac- response spectra of each measurement point are calculated,
teristic signal; however, the intermediate frequency interval respectively, and the results are shown in Figure 7. It can
(200 Hz–1000 Hz) is the best interval for detection among be seen from Figure 7(a) that the peak of point C is more
others. obvious in the low frequency interval, and the peak of point A
is prominent in the intermediate frequency interval, whereas
3.2. Influence of Torque on Harmonic Response of Spiral Bevel the vibration of each point is not visible at high frequency
Gear. In order to investigate the effect of torque (dynamic interval. According to Figure 7(b), each point has obvious
meshing force) and other excitations on the harmonic phase mutation inversion at about 600 Hz (intermediate
response of the spiral bevel gear system, tooth fracture frequency interval) and 1400 Hz (high frequency interval).
model is target object, and the torque of different sizes is Based on the above analysis and the conclusion in Section 3.1,
Journal of Control Science and Engineering 7

Figure 6: Measuring points position.

0.14 180

160
0.12
140
Deformation amplitude (m)

0.1
120
Phase angle (∘ )

0.08 100

0.06 80

60
0.04
40
0.02
20

0 0
0 200 400 600 800 1000 1200 1400 1600 1800 2000 0 200 400 600 800 1000 1200 1400 1600 1800 2000
Frequency (Hz) Frequency (Hz)

Measuring point A Measuring point D Measuring point A Measuring point D

Measuring point B Measuring point B
Measuring point C Measuring point C
(a) Deformation amplitude (b) Deformation phase angle

Figure 7: Harmonic responses of spiral bevel gear under different measuring points.

it can be seen that the measuring point near the working area (200 Hz–1000 Hz) is the best interval to determine whether
is the best test point when the system is monitored under the tooth is fractured.
intermediate frequency interval. (2) The effect of torque on the harmonic response of the
spiral bevel gear is quite little, and the change of excitation
4. Conclusion does not affect the fractured tooth monitoring.
(3) The amplitude of the vibration signal near the working
Based on the meshing principle and gear cutting process, the area is relatively strong, and it is the best measuring point area
tooth involute equation of the bevel gear is obtained, and the for detecting the fractured tooth signal.
parametric spiral bevel gear three-dimensional model and the
finite element model are established. Conflicts of Interest
The analysis results draw the following conclusions:
(1) Compared with the healthy tooth model, natural The authors declare that they have no conflicts of interest.
frequency in each order decreases in tooth fracture model,
and the natural frequency deviation of the fourth and sixth Acknowledgments
order is relatively large. Although the low frequency, inter-
mediate frequency, and high frequency interval section have The work described in this paper was fully supported by
tooth fracture signals, the intermediate frequency interval the National Natural Science Foundation of PRC (Grant nos.
8 Journal of Control Science and Engineering

51375226 and 51475226); Postgraduate Research and Practice [16] Z. Feng and C. Song, “Effects of geometry design parameters on
Innovation Program of Jiangsu Province; China Scholarship the static strength and dynamics for spiral bevel gear,” Inter-
Council’s support for joint research with Professor Yeping national Journal of Rotating Machinery, vol. 2017, Article ID
Xiong in University of Southampton. 6842938, 8 pages, 2017.
[17] Q. Fan, “Computerized modeling and simulation of spiral
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International Journal of
International Journal of Antennas and Active and Passive Advances in
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