Design Optimization of a Hybrid Spur Gear including Tooth Bending Effects

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A multiobjective design optimization technique for hybrid gears with sinusoidally shaped interlocks has been developed and applied to a hybrid spur gear. The hybrid gear concept consists of a metallic outer ring to support high tooth contact stress bonded to a composite inner web for weight reduction. Three design objectives were minimized for various geometric parameters controlling the composite–steel interface. Borg MOEA, a multiobjective evolutionary algorithm, was used to generate Pareto-optimal solutions for this design problem. Candidate designs were chosen from the Pareto-optimal set for more detailed analysis. From the results, we infer that the spur hybrid gear studied herein has the potential to decrease gear weight by approximately 27–45%, at the expense of a 22–34% increase in tooth pitch-point deflection, and that the optimal interface has between 15–20 cycles of the sinusoid with an amplitude of 0.25–0.35 mm.

Original languageEnglish (US)
Article number042009
JournalJournal of the American Helicopter Society
Issue number4
StatePublished - Oct 2022

All Science Journal Classification (ASJC) codes

  • General Materials Science
  • Aerospace Engineering
  • Mechanics of Materials
  • Mechanical Engineering


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