Characterization of a hybrid (Steel-composite) gear with various composite materials and layups

Hybrid gears, consisting of a composite body mated to a steel inner hub and outer rim of steel for the teeth, can afford significant weight savings, provided they can be manufactured to meet or exceed the functional characteristics of their all-steel counterparts. Here, a finite element, modal analysis of a hybrid gear is presented using three different composite materials, a combination of two of them, and various layup sequences to assess the expected dynamic variations of these gears. This hybrid gear model is validated through comparison to model results available in the literature. The material properties of the composites used in the analysis are estimated using vibration testing and finite element analysis of composite panels that match the layup sequence and material of those used in the gear. The predicted natural frequencies are also compared to those measured for previously-tested hybrid and all-steel gears.