Dynamic Response Analysis of Face Gear Pair with Tooth Breakage

A clear understanding of the relationship between the breakage size and dynamic signal changes is crucial to evaluating the health status of face gear operation. A method for calculating the meshing stiffness was proposed for face gear pairs with tooth breakage based on tooth contact analysis (TCA) and the finite element method. First, two cases of tooth breakage in the face gear pair were considered. The fracture line was parallel to the gear shaft and contact line, and the remaining position vector of the faulty tooth was solved by the TCA. The meshing stiffness was calculated in ABAQUS under different breakage sizes to study the influence of tooth breakage on the dynamic response. Several statistical indicators were used as fault-detection methods for different damage sizes. The bifurcation characteristics of a system with broken teeth were also discussed. The similarities and differences between the two cases of tooth breakage were analyzed in this study. Finally, the fault characteristics of the system under linear and nonlinear vibrations were compared. Tooth breakage primarily affects the amplitude and failure time of the meshing stiffness and produces periodic pulses and sidebands during acceleration. The periodic motion of the system changes to multiple quasi-periodic motions in a nonlinear vibration. Peak–peak and several dimensionless factors were the best indicators for detecting tooth breakage. The tooth breakage vibration in Case 2 was more violent and chaotic than that in Case 1. In a specific environment of nonlinear vibration, the periodic impact of broken teeth is weak and irregular, and the sidebands are difficult to identify.