Abstract
This paper presents the results of a conducted topology management optimization study based on the finite element analysis on a two-stage spur gear reducer housing body and cover using the SOLIDWORKS Simulation module. The main goal of the study is to optimize the overall weight of the reducer by thinning specific areas of the casted gearbox housing elements according to the calculated minimal strain energy. The topology optimization algorithm that is used in current research gives an optimal structural shape of the housing elements of the reducer with the largest stiffness, considering the given amount of mass that will be removed from the initial design space. The complete sequence of steps for conducting the topology management optimization study is shown, taking into account the constraints arising from the construction features and the method of manufacturing the housing elements of the gear reducer. Conclusions on the use of the topology optimization results are given and potential directions for further development of the approach are also identified.
Highlights
IntroductionFor obtaining the needed direction of movement and (usually high) transmission ratios, gear reducers may have one or more stages, being equipped with cylindrical gears (with parallel axes), conical gears (with concurrent axes), worm gears (with cross axles), or with a combination thereof
Toothed gear reducers are the most commonly used mechanisms for changing the motion parameters and torque in the operation of many different machine actuators, lifting and transporting devices in many manufacturing industries, and in automotive, shipbuilding, aerospace, etc.For obtaining the needed direction of movement and transmission ratios, gear reducers may have one or more stages, being equipped with cylindrical gears, conical gears, worm gears, or with a combination thereof
They usually are made with fixed axles but they can be movable, for example, in planetary or differential gear reducers, which results in a higher transmission ratio with smaller overall dimensions of the reducer
Summary
For obtaining the needed direction of movement and (usually high) transmission ratios, gear reducers may have one or more stages, being equipped with cylindrical gears (with parallel axes), conical gears (with concurrent axes), worm gears (with cross axles), or with a combination thereof. They usually are made with fixed axles but they can be movable, for example, in planetary or differential gear reducers, which results in a higher transmission ratio with smaller overall dimensions of the reducer. Suitable roller bearings are mounted and fixed by these two gear reducer housing parts in order to balance and transmit the reaction forces from the gears
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