Optimering av sintrade kugghjul
Powder Metal (PM) gears are machine element components which operate under the same principle as conventional gears, but, due to their intrinsic material characteristic need to be designed slightly different, and its manufacturing process offers advantages previously unobtainable by conventional steel gear manufacturing methods. The use of PM in similar applications, such as synchronous hubs, makes them a suitable candidate for production in such material. The current master thesis work focuses on gear design using PM by utilizing finite element method (FEM) to reduce weight and inertia taking into account root bending strength and tooth deflection.First a topological optimization is used to determine feasible candidates for different web designs which have as objective to reduce volume, similar topologies were shown during different loading conditions; and hence, this topology was chosen as a suitable candidate. A shape optimization of the topological candidate was performed having as state variables root bending strength, independent for compressive and tensile side of the tooth loading; and tooth deflection, which in concept can be correlated to static transmission error (TE).Another aspect in this thesis analysed is the possibility to incorporate non-trochoid root geometry, a trochoid root is always present when machining with a hob, into the gear root and hence reduce the stress concentration here. Due to the use of PM, a non-symmetric optimized root can be achieved and hence be optimizing compression and tension.Results showed significantly lower inertia, for example certain results showed 40% reduced when compared to solid gear, with adverse effects as increase in tooth deformation and increase in maximum principal stress. Peak to peak transmission error results of proposed web showed 17% lower result when compared to solid steel. Finally, root optimization showed marginally reduced maximum principal stress, but demonstrations potential with other geometries.