Validation of an industrial gearbox model for predicting vibro-acoustic behavior

Gear meshing represents a significant source of vibration excitation in gear units and shapes their acoustic behavior. The reliable prediction of the vibro-acoustic behavior of gear units in the early stages of development is crucial for optimizing gear tooth design. In this way, the requirements of load carrying capacity, service life as well as acoustic behavior can be achieved. Flexible Multi Body Simulation (MBS) models are increasingly employed for prediction and analysis of the vibro-acoustic behavior of gear units. The reliability of the predictions is heavily dependent on the accurate modelling of the individual flexible bodies, bearings, joints, gear wheels as well as meshing excitation. Therefore, this paper aims to demonstrate the systematic experimental validation of the component and assembly dynamics of an exemplary industrial gear unit model. The considered gear unit is modelled using a commercial MBS software and the validation is conducted in increasing order of complexity of components. For describing the vibro-acoustic behavior, it is not only necessary to validate the dynamic behavior of the assembly but also to accurately represent the dynamic excitation from gear meshing. For this, metrological inspections were conducted for the housing, shafts as well as gearings. The resulting axis deviations, shaft inclinations and gear tooth profiles were considered in the MBS model. Subsequently, the predictions of surface velocities at distinct points on the housing during operation are compared with corresponding experimental measurements. © 2023 The Authors.