A Novel Hybrid FEM–Dynamic Modeling Approach for Enhanced Vibration Diagnostics in a Two-Stage Spur Gearbox

Amine El Amli, Bilal El Yousfi, Abdenour Soualhi () and François Guillet
Additional contact information
Amine El Amli: LASPI Laboratory, Jean Monnet University, 42300 Roanne, France
Bilal El Yousfi: Ecole Militaire Polytechnique (EMP), BP 17, Bordj el Bahri, Algiers 16046, Algeria
Abdenour Soualhi: LASPI Laboratory, Jean Monnet University, 42300 Roanne, France
François Guillet: LASPI Laboratory, Jean Monnet University, 42300 Roanne, France

Energies, 2025, vol. 18, issue 9, 1-24

Abstract: The condition monitoring of gearboxes is crucial to ensuring the reliability and efficiency of modern industrial machinery. The accurate estimation of Time-Varying Mesh Stiffness (TVMS) is a key aspect of modeling gear meshing behavior and generating vibration signals used for fault diagnosis. In this study, TVMS is calculated by using the Refined Finite Element Method (R-FEM), which captures detailed gear-body compliance and distributed load effects. The dynamic model of a two-stage gearbox is then used to generate vibration responses under both healthy and faulty conditions. A comprehensive parametric sensitivity analysis is conducted on critical gear modeling parameters, including tooth profile deviations, mesh convergence in contact zones, assembly tolerance-induced interaxial variations, load-dependent stiffness variations, and hub-radius effects. Experimental validation using a gearbox test bench confirms that the proposed methodology accurately reproduces fault-specific harmonic components. These results indicate that the hybrid FEM–dynamic modeling approach effectively balances accuracy and computational efficiency, thereby providing a robust framework for advanced fault detection and maintenance strategies in gear systems.

Keywords: time-varying mesh stiffness; gearbox dynamics; fault diagnosis and detection; finite element method; vibration analysis (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
References: View complete reference list from CitEc
Citations:

Downloads: (external link)
https://www.mdpi.com/1996-1073/18/9/2176/pdf (application/pdf)
https://www.mdpi.com/1996-1073/18/9/2176/ (text/html)

Related works:
This item may be available elsewhere in EconPapers: Search for items with the same title.

Export reference: BibTeX RIS (EndNote, ProCite, RefMan) HTML/Text

Persistent link: https://EconPapers.repec.org/RePEc:gam:jeners:v:18:y:2025:i:9:p:2176-:d:1641415

Access Statistics for this article

Energies is currently edited by Ms. Agatha Cao

More articles in Energies from MDPI
Bibliographic data for series maintained by MDPI Indexing Manager ().