Design optimization of a hybrid spur gear

Sean Gauntt, Robert Campbell, Sean McIntyre

Research output: Contribution to conferencePaperpeer-review


This study develops an optimization technique for a sinusoidal interlock design of a hybrid spur gear consisting of a metallic outer ring to support high contact stress bonded to a composite inner web for weight reduction. Two objectives (mass and shear traction on the metal-composite interface under static loading conditions) were minimized for four design variables subject to two constraints. Borg MOEA, a multi-objective evolutionary algorithm developed at The Pennsylvania State University, and an in-house finite element solver were used to generate Pareto-optimal solutions to this design problem. Two of the designs were then analyzed in greater detail to determine stress distributions throughout the gear. In the future, this technique will be refined and applied to optimization of more representative rotorcraft gears, with the aim of reducing drive train weight and meeting performance requirements.

Original languageEnglish (US)
StatePublished - Jan 1 2019
EventVertical Flight Society's 75th Annual Forum and Technology Display - Philadelphia, United States
Duration: May 13 2019May 16 2019


ConferenceVertical Flight Society's 75th Annual Forum and Technology Display
Country/TerritoryUnited States

All Science Journal Classification (ASJC) codes

  • Aerospace Engineering
  • Control and Systems Engineering


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