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<p>This study presents an automated methodology for loaded tooth contact analysis of complex gear geometries based on the finite element method (FEM). Due to large stress/strain gradients, non-conformal contact analysis on 3D gear geometries requires numerous elements and high computational costs. The proposed method defines a&#xa0;candidate contact region for each active tooth surface and generates solid meshes with multiple discretization levels. This allows us to model the near-contact region with a&#xa0;mesh size of tens of microns, while adopting a&#xa0;much coarser mesh for the rest of the geometry. We investigate different strategies to manage the transition between the different mesh levels. This is a&#xa0;key challenge because smooth transition ensures numerical accuracy. As a&#xa0;solution, we employ internal contact elements to assemble nested mesh levels of mapped hexahedral elements. We analyze, as a&#xa0;test case, a&#xa0;variable-ratio rack-and-pinion drive used in steering systems. Convergence studies on contact pressure and sub-surface stress validate the accuracy of the results. Although the procedure was implemented using MATLAB scripts and Ansys APDL codes, it is applicable to various general-purpose FEM platforms. Its fully automated implementation makes it a&#xa0;versatile stand-alone module suitable for closed-loop gear design optimization.</p>

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Automated multilevel nested FE meshing and loaded tooth contact analysis of complex gear geometries

  • 期刊论文

  • 发表日期：

    2025年8月11日

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  • Martino Gulisano,
  • Eugeniu Grabovic,
  • Alessio Artoni,
  • Marco Gabiccini

摘要

This study presents an automated methodology for loaded tooth contact analysis of complex gear geometries based on the finite element method (FEM). Due to large stress/strain gradients, non-conformal contact analysis on 3D gear geometries requires numerous elements and high computational costs. The proposed method defines a candidate contact region for each active tooth surface and generates solid meshes with multiple discretization levels. This allows us to model the near-contact region with a mesh size of tens of microns, while adopting a much coarser mesh for the rest of the geometry. We investigate different strategies to manage the transition between the different mesh levels. This is a key challenge because smooth transition ensures numerical accuracy. As a solution, we employ internal contact elements to assemble nested mesh levels of mapped hexahedral elements. We analyze, as a test case, a variable-ratio rack-and-pinion drive used in steering systems. Convergence studies on contact pressure and sub-surface stress validate the accuracy of the results. Although the procedure was implemented using MATLAB scripts and Ansys APDL codes, it is applicable to various general-purpose FEM platforms. Its fully automated implementation makes it a versatile stand-alone module suitable for closed-loop gear design optimization.