An experimental and theoretical investigation of the influence of backlash on gear train vibro-impacts and rattle noise

Rattling is a perennial gear noise problem observed in various powertrain components ranging from manual transmissions to engine balancers and timing gear trains. Under lightly loaded conditions, gear systems that are subjected to input and/or output torque fluctuations exhibit vibro-impacts as tooth separations and coast-side contacts take place in the presence of backlash. Experimental set-ups that can impose tightly controlled torque fluctuations to single or multi-mesh gear train are used here to determine the sensitivity of the rattling noise levels to the magnitudes of backlash within wide ranges of torque fluctuation parameters. Torsional discrete models of the experimental set-ups were used to simulate these rattling motions and to predict impact velocity-based rattle severity indexes as a function of both excitation parameters and backlash magnitudes. Single-mesh results show that the larger backlash values result in higher noise levels in most of the cases. In case of double-mesh systems, the resultant noise levels and the corresponding rattle indices exhibit different sensitivities to backlash magnitudes depending on the excitation conditions.