A Comprehensive Approach for Analysing Optimized Profile-Shifted Gears with a Focus on Tribological Parameters

This study reports an improved design optimization method that incorporates profile shift and a modified tooth sum strategy to reduce both the weight and contact stress across the contact line of spur gears. The emphasis is on the optimal design of addendum-shifted spur gears with altered tooth sums, using a multi-objective optimization approach complemented by stress analysis and experimental validation. A detailed comparison of the optimization results reveals that addendum shifted gears with a negatively altered tooth sum achieve a weight reduction of 18.42% and a contact stress decrease of 9.17% compared to standard gears. Experimental evaluations further confirm that addendum modified and negatively altered tooth sum gears exhibit an 11.68% improvement in efficiency over standard gears. The experimental results demonstrate that there is 24.41% less reduction in tooth thickness, a 10.83% lesser decrease in surface roughness, a 21.74% lesser rise in oil bath temperature, and a 53.28% less rise in gear tooth contact surface temperature of the negatively altered tooth sum in comparison to the standard gear set. This indicates that there is a possibility of obtaining improved performance in profile modified altered tooth sum gear.