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<p>Surface wear poses a critical challenge in gear systems, accelerating premature failures that risk operational safety and equipment longevity. This study investigates wear-induced health-instability dynamics in spur gear systems with installation error (IE). A multi-state engaging nonlinear dynamic model incorporating time-varying meshing stiffness and load distribution coefficient effected by IE is developed. Based on the tooth wear failure condition and Archard’s wear model including nonlinear dynamic engaging force, a wear-induced health-instability domain is established for a spur gear pair. The erosion mechanism of health-instability basins is revealed with the co-variation of parameter and initial values by using a multi-initial bifurcation diagram, bifurcation dendrogram, and basin of attraction. The results show that IE decreases the contact ratio of the gear pair and lowers the meshing stiffness profile, shrinking double-tooth mesh zones and expanding single-tooth regions. Dynamic meshing force exceeding the health-domain threshold emerges as the primary instability driver. Bifurcation analysis shows that incomplete bifurcation leads to coexistence behaviors that gradually erode stability basins. Effectively matching parameters and initial values enhances gear systems’ dynamic performance and longevity.</p>

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Investigating wear-induced health-instability dynamics in spur gear systems with installation error

  • 期刊论文

  • 发表日期：

    2025年5月27日

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  • Jian-Fei Shi,
  • Chuang Han,
  • Li-Xia Chen,
  • Wu-Yin Jin

摘要

Surface wear poses a critical challenge in gear systems, accelerating premature failures that risk operational safety and equipment longevity. This study investigates wear-induced health-instability dynamics in spur gear systems with installation error (IE). A multi-state engaging nonlinear dynamic model incorporating time-varying meshing stiffness and load distribution coefficient effected by IE is developed. Based on the tooth wear failure condition and Archard’s wear model including nonlinear dynamic engaging force, a wear-induced health-instability domain is established for a spur gear pair. The erosion mechanism of health-instability basins is revealed with the co-variation of parameter and initial values by using a multi-initial bifurcation diagram, bifurcation dendrogram, and basin of attraction. The results show that IE decreases the contact ratio of the gear pair and lowers the meshing stiffness profile, shrinking double-tooth mesh zones and expanding single-tooth regions. Dynamic meshing force exceeding the health-domain threshold emerges as the primary instability driver. Bifurcation analysis shows that incomplete bifurcation leads to coexistence behaviors that gradually erode stability basins. Effectively matching parameters and initial values enhances gear systems’ dynamic performance and longevity.