Rattle noise on a die-cast aluminium bevel gear pair
Tracing a tick at tooth-mesh frequency to its source and redesigning the bevel set within material and process limits.
- Industry
- Access automation
- Year
- 2024
- Sheet
- 4 / 7
- Client
- Manufacturer of automation systems
- Duration
- About 4 weeks
- Tools
- RecurDyn, KISSsoft
- Standards
- ISO 10300
Bevel pair at 90° with virtual control points on the housingSchematic, not to scale
The question
A 90°, 1:1 bevel pair in sand-blasted die-cast aluminium runs at low speed (around 75 rpm) and low torque. It produced a ticking rattle at tooth-mesh frequency, both unloaded and under load.
What the customer received
- NVH characterisation of the current design
- Optimised bevel gear geometry
- Before-and-after simulation and presentation of results
Services: NVH and multibody simulation, Gear and transmission calculation
What we did
- Preliminary NVH assessment: excitation orders and characteristic frequencies in a Campbell diagram.
- RFM model in RecurDyn with the gears and detailed bearing geometry.
- Accelerations at virtual control points on the housing, placed where they can later be compared with measurements.
- Optimised the bevel geometry in KISSsoft within the customer’s material and process constraints, then simulated the new pair against the original.
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