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<p>The ongoing transition towards electromobility and the consequent absence of combustion engine noise have drawn attention to gear noise reduction. To analyze and optimize the NVH (noise, vibration and harshness)—characteristics of a&#xa0;gearbox numerically, high-quality excitation data is essential. The primary source of excitation is the force generated by the contact of meshing teeth, which are transmitted to the housing. As real gears usually have manufacturing deviations and surface modifications that result in a&#xa0;non-ideal tooth geometry, which can notably influence the transmission error and contact forces, these effects should be considered when predicting the excitation. The simulation model of a&#xa0;real-world single-flank test bench allows us to study the behavior of a&#xa0;gear pairing and to calculate the necessary excitation data for a&#xa0;NVH calculation. The simulation is validated by comparing the simulation results with test bench measurements. Finally, a&#xa0;comparison is made between a&#xa0;simulation with ideal gears and gears with measured tooth geometries. The results show that the measured, non-ideal geometry results in a&#xa0;higher transmission error and higher forces in the bearings.</p><p>In this study a&#xa0;multibody simulation model, that can handle complex real-world tooth geometry deviations, is presented. For this purpose, the multibody simulation software FreeDyn is used in combination with the Polygonal Contact Model. This study is not positioned as an industry-specific, fully validated tool for gear design. It is not intended to derive any new insights in the field of NVH or the gear engineering field in general, but rather to show the capabilities of such a&#xa0;simulation model.</p>

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Multibody simulation of spur gears using 3D contact modeling and real-world tooth geometry

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年7月10日

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  • Jürgen Grünberger,
  • Wolfgang Steiner,
  • Wolfgang Witteveen

摘要

The ongoing transition towards electromobility and the consequent absence of combustion engine noise have drawn attention to gear noise reduction. To analyze and optimize the NVH (noise, vibration and harshness)—characteristics of a gearbox numerically, high-quality excitation data is essential. The primary source of excitation is the force generated by the contact of meshing teeth, which are transmitted to the housing. As real gears usually have manufacturing deviations and surface modifications that result in a non-ideal tooth geometry, which can notably influence the transmission error and contact forces, these effects should be considered when predicting the excitation. The simulation model of a real-world single-flank test bench allows us to study the behavior of a gear pairing and to calculate the necessary excitation data for a NVH calculation. The simulation is validated by comparing the simulation results with test bench measurements. Finally, a comparison is made between a simulation with ideal gears and gears with measured tooth geometries. The results show that the measured, non-ideal geometry results in a higher transmission error and higher forces in the bearings.

In this study a multibody simulation model, that can handle complex real-world tooth geometry deviations, is presented. For this purpose, the multibody simulation software FreeDyn is used in combination with the Polygonal Contact Model. This study is not positioned as an industry-specific, fully validated tool for gear design. It is not intended to derive any new insights in the field of NVH or the gear engineering field in general, but rather to show the capabilities of such a simulation model.