An investigation into the effect of tooth profile errors on gear rattle

In previous work, experimental data have demonstrated the severity of idling gear rattle depends not only on the amplitude, but also the phase of an external sinusoidal forcing. One possible explanation for this is in small tooth profile errors. In this paper, we investigate this hypothesis, by deriving an equation of motion incorporating an error function and losses at the mesh interface, values of which are obtained from experimental data. By solving the equations of motion, theoretical gear rattle trajectories are obtained. Theoretical and experimental trajectories are then compared, by way of time domain plots as well as via contour plots linking the amplitude of backlash oscillation to the amplitude and phase of input forcing. For most profile error functions, good agreement is achieved between the model and experimental data. In the case where the profile errors are dominated by misalignment between the gear and shaft centres agreement is less good and suggestions of areas of further study required for model refinement are proposed.