This paper proposes a new procedure for formulating the gear rattle type problem analytically before attempting a numerical solution. This step is necessary due to the nature of the mathematical formulation with vibro-impacts, which is non-analytical and hence causes numerical “stiffness”. The procedure is essentially an “intelligent” pre-processing stage and is based on our vast experience in simulating such systems. Important concepts such as order reduction, gear contact ratio, appropriate choice of non-dimensionalization parameters are illustrated through several examples.

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