Abstract: In this work a non-linear dynamic model of spur gear transmissions previously developed by the authors is extended to include both desired (relief) and undesired (manufacture errors) deviations in the tooth profile. The model uses a hybrid method for the calculation of meshing forces, which combines FE analysis and analytical formulation, so that it enables a very straightforward implementation of the tooth profile deviations. The model approach handles well non-linearity due to the variable meshing stiffness and the clearances involved in gear dynamics, also including the same phenomena linked to bearings. In order to assess the ability of the model to simulate the impact of the deviations on the transmission dynamics, an example is presented including profile deviations under different values of transmitted torque. Several results of this example implementation are presented, showing the model's effectiveness.

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