Chaos Suppression in Spiral Bevel Gears Through Profile Modifications

Spiral bevel gears are used in a wide range of industries, such as automotive and aerospace, to transfer power between intersecting axes. However, a certain level of vibration is always present in the systems, primarily due to the complex dynamic forces generated during the meshing of the gear teeth affected by the tooth profile. To address these challenges, this research developed a comprehensive dynamic model with eight degrees of freedom, capturing both translational and rotational movements of the system’s components. The study focused on evaluating the effects of two different tooth profile modifications, namely topology and flank modifications, on the vibration characteristics of the system. The system comprised a spiral bevel gear pair with mesh stiffness in forward rotation. The results highlighted that optimizing the tooth profile and minimizing tooth surface deviation significantly reduce vibration amplitudes and improve dynamic stability. These findings not only enhance the performance and lifespan of spiral bevel gears but also provide a robust foundation for the design and optimization of advanced gear systems in industrial applications, ensuring higher efficiency and reliability. In this paper, it was observed that some modifications led to a 68% reduction in vibration levels. Additionally, three modifications helped improve the vibrational behavior of the system, preventing chaotic behavior, which can lead to system failure, and transforming the system’s behavior into periodic motion.