Failure prediction of geared mechanism at multiple gearshift configuration by utilizing the experimental design and integer programming method

This research paper aims to model the failure pattern based on safety factor data at different gear shift configurations for a compound planetary gear assembly. An optimization approach is expounded in this work, which aims to reduce the developed stresses within the gearbox assembly while considering all the gear-shift configurations. Computer-aided engineering software, in conjunction with the Design of Experiments technique, is employed to analyze the computer-aided design model of the gear assembly with gear shift configurations of gear members. The method of integer programming provides an optimal solution by deducing a safety factor value, indicating the system's capacity to withstand the specified loading condition. Here in the proposed safety factor model emphasizes on the failure analysis for a Ravigneaux gearbox, based on the material failure theory, to enhance the load-bearing capacity for all shift configurations of the compound epicyclic gear assembly. The regression models for three safety factor values based on maximum equivalent stress, maximum shear stress, and fatigue exhibit a p-value close to zero. High significance has been observed with the thermal condition, suggesting that good lubrication is required to maintain the gearbox at an optimal temperature.