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Design and Optimization of Gears Using Lattice Structure for Additive Manufacturing

Pourrokni Salehan, Sepehr | 2021

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  1. Type of Document: M.Sc. Thesis
  2. Language: Farsi
  3. Document No: 54468 (08)
  4. University: Sharif University of Technology
  5. Department: Mechanical Engineering
  6. Advisor(s): Khodaygan, Saeed
  7. Abstract:
  8. Gears are a major component of many transmission systems. nowadays, improving the operating conditions and reducing the weight of the gears is one of the most needed issues in the industry. This dissertation aims to find the optimal structure of gear under different load cases and reduce its weight optimally. In this regard, topology optimization is used to develop the gear structure.In this research, two areas of bio-inspired design and additive manufacturing are used to achieve goals. These two areas can make good use of each other's potentials and achieve results that were not previously possible with traditional methods of design and manufacturing. First, an introduction and history of additive fabrication are presented, then according to the characteristics of this method, its connection point with bio-inspired design is shown and then the subject of bio-inspired design is discussed, which is a primary introduction to topology optimization method.Implementing topology optimization is done only for the critical part of the gear and then by extending it to the whole gear, the final result is achieved. For this purpose, a critical model of a gear tooth is created and topology optimization is implemented in Abaqus software by applying constraints and loading.Most designs created by topology optimization have complex geometries, and in many cases, this complex geometry needs to be simplified. For this reason, the optimization result is output and a redesign step is performed on it in SolidWorks to improve its manufacturability. In addition, in this study, the dynamic performance of the proposed gear is examined by the concept of mesh stiffness and the results are compared with a simple tooth.After creating the final model, it's analyzed using the finite element method and a comparison is made with the simple model. In addition to all these cases, the modal analysis of the new gear is performed and the results are examined. Comparing this design with a simple case, it was concluded that the final proposed design, in addition to significant weight loss and good static performance, was able to have a good mesh stiffness and respond to the dynamic performance of the gear while responding to stresses
  9. Keywords:
  10. Gears ; Topology Optimization ; Bioinspired Design ; Additive Manufacturing ; Gear Mesh Stiffness

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