Achieving faster computational efficiency in gear dynamic simulation remains a critical challenge due to the strong localized nonlinearities inherent in these systems. In this work, a nonlinearity separation and static-dynamic synthesis (NSSDS) method is proposed to isolate localized nonlinearities at gear and bearing interfaces. NSSDS pioneers the application of a static-dynamic synthesis basis for model order reduction and effectively combines static deformation characteristics with dynamic modal information to accelerate gear dynamic calculation substantially while preserving accuracy in capturing nonlinear behaviors. Both the numerical simulation and experimental studies demonstrate the accuracy and computational efficiency of NSSDS. Nonlinear dynamic analysis shows that NSSDS effectively captures the dominant static deformation in geared rotor systems, enabling highly efficient and accurate dynamic analysis with considerably reduced truncation orders. NSSDS outperforms the traditional mode superposition method by incorporating static deformation characteristics. So it is particularly suitable for rapid vibration simulation of complex nonlinear gear systems. This fast algorithm provides rapid, accurate simulation of complex nonlinear behavior, which is crucial for vibration analysis and dynamic design optimization of gear transmission systems.
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