Research on Gear Modification Optimization of High-Speed Heavy-Load Reducer Based on Romax

This paper investigates the gear whine problem in a high-speed heavy-load reducer. A rigid-flexible coupled multibody dynamic model of the reducer is established using Romax. Transmission error, unit load, tooth root stress, and contact stress are used as optimization objectives. A comprehensive gear micro-modification method including lead crowning, lead slope, involute crowning, and involute slope is proposed, and a genetic algorithm is employed for optimization. The peak-to-peak transmission error [TE(p-p)] decreased from 0.27 μm to 0.19 μm for the first-stage gear pair and from 2.67 μm to 0.96 μm for the second-stage gear pair, corresponding to reductions of 29.63% and 64.04%, respectively. The maximum contact stresses decreased from 507 MPa to 488 MPa (3.75%) and from 627 MPa to 618 MPa (1.44%) for the first- and second-stage gear pairs, respectively. The radiated noise of the gearbox was reduced by about 10 dB on average. The proposed method provides a reference for the microgeometry design of high-speed heavy-load reducers.