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Application of tabular contact search method to multibody gear dynamics simulation with tooth surface imperfections

In this investigation, an integrated numerical procedure for multibody gear dynamics simulation is developed using the tabular contact search method. Existing online contact search algorithms, which are widely used in multibody dynamics simulation, lead to extensive computational burden if detailed tooth surface geometry described by CAD or measured data points are considered with geometric imperfections. In the numerical procedure developed in this study, the contact geometry analysis based on the nonconformal contact condition is performed using the detailed tooth surface description prior to the dynamic simulation, and then the contact point as well as the tooth geometry at the contact point stored in the look-up contact tables are used to determine mesh forces in the multibody gear dynamics simulation. This allows for detecting multi-point contact without any iterative procedures, and the contact point on the back side of the tooth can also be considered by switching look-up contact tables in a straightforward manner. Furthermore, it is demonstrated that discontinuous contact event caused by the tooth surface imperfection can be predicted using a combined nodal and nonconformal contact search algorithm developed in this study. Several numerical examples are presented in order to demonstrate the use of the numerical procedure developed in this investigation.