Author(s): Rami EL-Saad

Abstract: Gear trains are critical components in mechanical systems requiring precise power transmission, such as in automotive transmissions, robotics, aerospace drives, and industrial machinery. Accurate modeling of their dynamic behavior is essential to improve performance, reliability, and longevity. This study presents a comprehensive multibody dynamics simulation of a compound spur gear train using MSC ADAMS, a leading software for virtual prototyping of mechanical systems. The model includes realistic gear geometry, material properties, frictional contact, and applied torques to simulate real-world conditions. The simulation focuses on evaluating rotational velocities, torque transmission, contact forces, and vibrational response over time. Key performance indicators such as gear backlash, stress distribution, and mesh stiffness were analyzed using MSC ADAMS' integrated tools. Validation was conducted through theoretical calculations using standard gear design equations and cross-verification with existing literature data. Analytical comparisons show that simulation results deviate by less than 5%, indicating high model accuracy. Additionally, a sensitivity analysis was performed to examine the influence of gear module and face width on system performance. The results demonstrate the effectiveness of MSC ADAMS in predicting the dynamic behavior of gear trains, providing valuable insights for design optimization and early fault detection. This research contributes to the growing body of digital engineering techniques in machine element design and supports the integration of simulation-driven workflows in mechanical engineering applications.

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