A Feasibility Analysis to Use Topological Optimization in Gear Design

The paper conducts a feasibility analysis for using a topology optimization (TO) when designing the gears for advanced engines.

The goal of TO is to find an optimal material distribution in designing area for given loads with constraints consideration. This study performs 3D computations using a finite-element analysis.

Optimization of the certain statements of the problem has been provided. In case 1 an increasing rigidity of diaphragm of the helical gear with decreasing mass was specified, as a criterion. As a result of optimization there were two conical sections getting into one thin wall, connected at the face where the axial force is applied. Some aviation engine and helicopter transmission schemes have a similar embodiment of a diaphragm of the helical gear. In case 2 the frequency detuning was carried out. The result is a complicated design, containing closed cavities, so it is hard to manufacture it by traditional manufacturing methods. Case 3 solves a problem of increasing torsional rigidity with mass restrictions. The optimized design has a splitting diaphragm and a closed cavity.

The final calculation is carried out for case 1. As a result, maximum displacements for initial and optimized designs are obtained. The analysis and comparing results have shown that the optimized design has over 2 times increased diaphragm rigidity as compared to the initial design, with mass being 10 % less and equivalent stresses reduced by 13%.

The analysis of the results has shown that TO can be used in designing gears taking into account the requirements for mass, rigidity, natural frequencies. It is advisable to refine a design of components using parametric optimization after TO and engineering study of results.

topology optimization, gears

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