Optimum weight design of functionally graded material gears

Traditional gear weight optimization methods consider gear tooth number, module, face width or other dimension parameters of gear as design variables. However, due to the complicated form and geometric features peculiar to the gear, there will be large amounts of design parameters in gear design, and the influences of gear parameters changing on gear trains, transmission system and the whole equipment have to be taken into account, which increases the complexity of optimization problem. This paper puts forward to apply functionally graded materials (FGMs) to gears and then conduct the optimization. According to the force situation of gears, the material distribution form of FGM gears is determined. Then based on the performance parameters analysis of FGMs and the practical working demands for gears, a multi-objective optimization model is formed. Finally by using the goal driven optimization (GDO) method, the optimal material distribution is achieved, which makes gear weight and the maximum deformation be minimum and the maximum bending stress do not exceed the allowable stress. As an example, the applying of FGM to automotive transmission gear is conducted to illustrate the optimization design process and the result shows that under the condition of keeping the normal working performance of gear, the method achieves in greatly reducing the gear weight. This research proposes a FGM gears design method that is able to largely reduce the weight of gears by optimizing the microscopic material parameters instead of changing the macroscopic dimension parameters of gears, which reduces the complexity of gear weight optimization problem.