Study of Improving Spur Gears with the Generative Design Method

Abstract

Gears are one of the most commonly used parts in different manufacturing industries because of their functionality, and so the question of how to improve the geometry of these parts was always in the open. The research paper brings up the idea of reducing the material volume used in the manufacturing process by using a generative design method, meaning a free-flowing design using generative design software. The CAD model is subjective to parameters that are targeted in the program (volume, mass, safety factor) that are a frame of reference to develop different iterations from which we chose 5 of them. A finite element analysis is made to compare the generative version with the non-modified CAD to see the differences in behavior. These results are used to choose the best iteration of the gear. The parts modified as well as the non-modified ones are manufactured using different additive manufacturing technologies. An analysis is made to see the differences in terms of mechanical characteristics by making tests for surface durability, tensile strength, and bending. The results of the analysis show a 50% decrease in material volume without compromising the structural functionality.