Multi-objective topology optimization for bevel gear and geometrical reconstruction

Usually the gear modification is a main measure to reduce the vibration and noise of the gears, but in view of the complexity of the gear modification, topology optimization method was used to optimize the structure of the gear. The minimum volume was set as the direct optimization goal. To achieve the target of reducing contact stress, tooth root bending stress and improving flexibility, the upper bound of the stress and lower bound of the flexibility were set appropriately, thus realizing multi-objective optimization indirectly. A method for converting topology result into parametric CAD model which can be modified was presented, by fitting the topology result with simple straight lines and arcs, the model can be smoothed automatically, after further regulating, the geometry reconstruction was finished. After topology optimization, the resulting structure and properties of the gear are consistent with cavity gear. While reducing the weight of the gear, the noise can be reduced and its life would be extended through increasing flexibility and reducing tooth root stress.