Topological Optimization of Gear Wheels

The authors developed an algorithm for the topological optimization of gear wheels to reduce their weight. The parametric model of a standard gear wheel was developed following the design and revision calculations with the set input data. The optimization produced gear wheels with the target weight retention value of 80%, 60%, and 40%. For the obtained gear wheel designs, the authors analyzed component weight, strains, and movements and determined the specific cog rigidity. All of the research was carried out taking into account the contact patch size. The authors obtained a dependency between the specific rigidity of a cog and two variable geometry parameters: gear ring thickness and wheel thickness. The von Mises stress values in the loaded parts of gear wheels were compared with the permitted stress values, and the weight, movements, and specific rigidity of optimized gear wheels were compared with the similar parameters of a standard gear wheel. The authors also studied the correlations between the cog production precision and the specific rigidity of cogs. The developed topological gear wheel optimization algorithm will be useful for engineers designing gear wheels with minimum weight requirements. The stress and rigidity parameters of gear wheels with different wheel mass retention values and variable wheel and gear ring thickness values can be used for the optimization of design tasks.