Topology Optimization of Automotive Gear using Fea

Abstract

Gears are the key elements used to transmit power or motion from on shaft to another and it has wide range of applications. It's one of the major application is in the automobile gear box. Generally, gears fail when the working stress exceeds than the maximum permissible value. Here the generated stresses are directly in relation to amount power produced inside an engine, as well as also on torque. This study mainly focuses to identify the magnitude of the bending stresses generated in the selected gear set of CVT of a two-wheeler during power transmission as well as also tried to find different ways for reducing weight of the gear. Hence integrating the feature of topology optimization as a part of weight reduction over an existing part is considered as the key parameter of assessment for this work. In this study, gears of CVT gearbox of two-wheeler is analyzed for static loading under the application of tangential load resulting from maximum torque in the given application. After the study of the stress distribution on existing gears, the material removal area for weight reduction is identified on selected gears then the same study for stress distribution is carried out for proposed designs of topological optimization. Hence the both existing and proposed optimized designs are analyzed under static structural analysis for same loading and results for stress distribution are compared.