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<p>This paper explores the development and validation of a&#xa0;macroscopic simulation framework tailored for analyzing spur gears made from hybrid and porous materials called HyPo materials. These materials combine a&#xa0;steel surface layer with a&#xa0;porous metal foam core, offering a&#xa0;novel approach to lightweight machine components. The simulation uses the Finite Element Method (FEM) to model the tooth root stress, angular deviation, and contact ratio under load for HyPo gear pairings, adapting a&#xa0;pre-existing software framework originally designed for fiber-reinforced plastic gears. The framework was validated against standard steel gear calculations and showed good agreement with analytical methods. Two studies were carried out to investigate the effects of surface layer thickness and foam porosity on gear performance. The performance was evaluated using three performance metrics: tooth root stress, angular deviation, and contact ratio under load. In both studies, increased stiffness, resulting from a&#xa0;thicker surface layer or higher foam porosity, led to an improvement of tooth root stress and angular deviation, whereas the contact ratio was influenced negatively. The studies further indicate that HyPo gears may produce less noise than conventional steel gears, as their contact ratio under load is higher. These results highlight the influence of the mechanical properties of the foam core and the surface layer thickness. The presented study constitutes a&#xa0;foundational element within a&#xa0;larger, ongoing research effort aimed at systematically characterizing and optimizing HyPo gear systems. The simulation framework developed here provides a&#xa0;versatile tool for future research on HyPo gears and can be adapted to different materials and gear configurations.</p>

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Simulative investigations of the operating behaviour of spur gears made of the material pair steel and aluminium foam

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年9月17日

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  • Maximilian Alexander Bähr,
  • Oliver Koch,
  • Manuel Oehler

摘要

This paper explores the development and validation of a macroscopic simulation framework tailored for analyzing spur gears made from hybrid and porous materials called HyPo materials. These materials combine a steel surface layer with a porous metal foam core, offering a novel approach to lightweight machine components. The simulation uses the Finite Element Method (FEM) to model the tooth root stress, angular deviation, and contact ratio under load for HyPo gear pairings, adapting a pre-existing software framework originally designed for fiber-reinforced plastic gears. The framework was validated against standard steel gear calculations and showed good agreement with analytical methods. Two studies were carried out to investigate the effects of surface layer thickness and foam porosity on gear performance. The performance was evaluated using three performance metrics: tooth root stress, angular deviation, and contact ratio under load. In both studies, increased stiffness, resulting from a thicker surface layer or higher foam porosity, led to an improvement of tooth root stress and angular deviation, whereas the contact ratio was influenced negatively. The studies further indicate that HyPo gears may produce less noise than conventional steel gears, as their contact ratio under load is higher. These results highlight the influence of the mechanical properties of the foam core and the surface layer thickness. The presented study constitutes a foundational element within a larger, ongoing research effort aimed at systematically characterizing and optimizing HyPo gear systems. The simulation framework developed here provides a versatile tool for future research on HyPo gears and can be adapted to different materials and gear configurations.