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<p>In the design of gearboxes, gears without manufacturing deviations are usually assumed. Due to deviations in the manufacturing of individual components, the real, tolerance-affected system no longer corresponds to the idealized system of the design. As a&#xa0;result, the actual characteristics differ from the calculated target properties. Within the framework of the BMWE-funded research project Opt4E, the influence of manufacturing deviations on gearbox characteristics in terms of load capacity, efficiency, and dynamic behavior is systematically analyzed. A&#xa0;full factorial simulation or a&#xa0;meaningful analysis using design and analysis of computer experiments (DACE) methods across all tolerance bands is usually not feasible due to the exponential increase in required simulation runs with expanding tolerance dimensions and ranges. Therefore, alternative approaches are to be explored. Underlying simulations are carried out in the first step using the loaded tooth contact analysis (LTCA) program RIKOR of the research association for drive technology (FVA). These initial calculation results are subject to a&#xa0;global sensitivity analysis (GSA), which can determine the relevance of individual influencing factors and their interactions within the defined parameter space. The analysis identifies the dominant deviations for each performance indicator at a&#xa0;moderate vehicle speed, assuming uniform load sharing across the active tooth pairs. Load-carrying capacity is significantly influenced by bearing misalignments (v-direction, pinion) and helix slope deviations, while efficiency is mainly influenced by profile slope deviations. In terms of NVH behavior, bearing misalignments (v-direction, pinion) and flank twist are dominant deviations. These results of the sensitivity analysis form the basis for further investigations.</p>

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The impact of manufacturing deviations on gearbox performance using a global sensitivity analysis

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年6月23日

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  • Florian Oberneder,
  • Thomas Papadopoulos,
  • Patrick Strobl,
  • Michael Otto,
  • Karsten Stahl

摘要

In the design of gearboxes, gears without manufacturing deviations are usually assumed. Due to deviations in the manufacturing of individual components, the real, tolerance-affected system no longer corresponds to the idealized system of the design. As a result, the actual characteristics differ from the calculated target properties. Within the framework of the BMWE-funded research project Opt4E, the influence of manufacturing deviations on gearbox characteristics in terms of load capacity, efficiency, and dynamic behavior is systematically analyzed. A full factorial simulation or a meaningful analysis using design and analysis of computer experiments (DACE) methods across all tolerance bands is usually not feasible due to the exponential increase in required simulation runs with expanding tolerance dimensions and ranges. Therefore, alternative approaches are to be explored. Underlying simulations are carried out in the first step using the loaded tooth contact analysis (LTCA) program RIKOR of the research association for drive technology (FVA). These initial calculation results are subject to a global sensitivity analysis (GSA), which can determine the relevance of individual influencing factors and their interactions within the defined parameter space. The analysis identifies the dominant deviations for each performance indicator at a moderate vehicle speed, assuming uniform load sharing across the active tooth pairs. Load-carrying capacity is significantly influenced by bearing misalignments (v-direction, pinion) and helix slope deviations, while efficiency is mainly influenced by profile slope deviations. In terms of NVH behavior, bearing misalignments (v-direction, pinion) and flank twist are dominant deviations. These results of the sensitivity analysis form the basis for further investigations.