Abstract
Gearboxes find extensive use in a wide variety of fields. Over the years, a great deal of research has been devoted to prevention of gear failures and gear noise. Devising an optimal design is often considered as the most important stage in the development of a new gearbox. Similar to the varying requirements of different applications, the directions and method of gearbox design optimization are also varied. Usually, gear geometry optimization has a great influence on the strength and transmission error which is the excitation factor that affects the noise level. The main objective of this article is to summarize common optimization methods that have been recently studied by scholars. Moreover, a review of recent patents status quo, both domestic and overseas, is carried out.
Similar content being viewed by others
Abbreviations
- b :
-
Face width, mm
- d 1 :
-
Reference diameter of pinion, mm
- u :
-
Gear ratio
- Y B :
-
Rim thickness factor
- Y DT :
-
Deep tooth factor
- Y F :
-
Tooth form factor
- Y NT :
-
Life factor (root stress)
- Y RrelT :
-
Relative surface factor
- Y S :
-
Stress correction factor
- Y ST :
-
Stress correction factor (reference test gear)
- Y X :
-
Size factor (root stress)
- Y β :
-
Helix angle factor (root stress)
- Y δrelT :
-
Relative notch sensitivity factor
- F :
-
Load on arbitrary position of tooth flank, N
- F t :
-
Nominal transverse tangential load at reference cylinder per mesh, N
- S H :
-
Safety factor for surface durability
- S R :
-
Safety factor for bending strength
- K A :
-
Application factor
- K Fα :
-
Transverse load factor (root stress)
- K Fβ :
-
Face load factor (root stress)
- K Hα :
-
Transverse load factor (contact stress)
- K Hβ :
-
Face load factor (contact stress)
- K V :
-
Dynamic factor
- K γ :
-
Mesh load factor
- Z B, D :
-
Single pair tooth contact factor
- Z E :
-
Elasticity factor, N/mm2
- Z H :
-
Zone factor
- Z L :
-
Lubricant factor
- Z NT :
-
Life factor (contact stress)
- Z R :
-
Roughness factor
- Z V :
-
Velocity factor
- Z W :
-
Work hardening factor
- Z X :
-
Size effect factor (contact stress)
- Z β :
-
Helix angle factor (contact stress)
- Z ε :
-
Contact ratio factor
- σ F :
-
Tooth root stress, MPa
- σ FG :
-
Tooth root stress limit, MPa
- σ Film :
-
Nominal stress number (bending), MPa
- σ F0 :
-
Nominal tooth root stress, MPa
- σ H :
-
Contact stress, MPa
- σ HG :
-
Pitting stress limit, MPa
- σ Hlim :
-
Allowable stress number (contact), MPa
- σ H0 :
-
Nominal contact stress, MPa
- T.E. :
-
Transmission Error
- DM :
-
Direct Method
- ETM :
-
Elapsed Time Method
- PPTE :
-
Peak to Peak Transmission Error
References
Palermo, A., Britte, L., Janssens, K., Mundo, D., and Desmet, W., “The Measurement of Gear Transmission Error as an NVH Indicator: Theoretical Discussion and Industrial Application via Low-Cost Digital Encoders to an All-Electric Vehicle Gearbox,” Mechanical Systems and Signal Processing, Vol. 110, pp. 368–389, 2018.
Tran, T. L., Pham, A. D., and Ahn, H.-J., “Lost Motion Analysis of One Stage Cycloid Reducer Considering Tolerances,” International Journal of Precision Engineering and Manufacturing, Vol. 17, No. 8, pp. 1009–1016, 2016.
Kim, J.-G., Park, Y.-J., Lee, G.-H., and Kim, J.-H., “An Experimental Study on the Effect of Carrier Pinhole Position Errors on Planet Gear Load Sharing,” International Journal of Precision Engineering and Manufacturing, Vol. 17, No. 10, pp. 1305–1312, 2016.
Fang, S., Liu, Y., Wang, H., Taguchi, T., and Takeda, R., “Research on the Compensation Method for the Measurement Error of Cycloidal Gear Tooth Flank,” International Journal of Precision Engineering and Manufacturing, Vol. 15, No. 10, pp. 2065–2069, 2014.
Wei, J., Shu, R., Qin, D., Lim, T. C., Zhang, A., and Meng, F., “Study of Synchronization Characteristics of a Multi-Source Driving Transmission System under an Impact Load,” International Journal of Precision Engineering and Manufacturing, Vol. 17, No. 9, pp. 1157–1174, 2016.
Concli, F., “Low-Loss Gears Precision Planetary Gearboxes: Reduction of the Load Dependent Power Losses and Efficiency Estimation through a Hybrid Analytical-Numerical Optimization Tool,” Forschung im Ingenieurwesen, Vol. 81, No. 4, pp. 395–407, 2017.
Sun, W., Ding, X., Wei, J., Hu, X., and Wang, Q., “An Analyzing Method of Coupled Modes in Multi-Stage Planetary Gear System,” International Journal of Precision Engineering and Manufacturing, Vol. 15, No. 11, pp. 2357–2366, 2014.
Wei, J., Lv, C., Sun, W., Li, X., and Wang, Y., “A Study on Optimum Design Method of Gear Transmission System for Wind Turbine,” International Journal of Precision Engineering and Manufacturing, Vol. 14, No. 5, pp. 767–778, 2013.
Zhang, Q., Kang, J., Dong, W., and Lyu, S., “A Study on Tooth Modification and Radiation Noise of a Manual Transaxle,” International Journal of Precision Engineering and Manufacturing, Vol. 13, No. 6, pp. 1013–1020, 2012.
He, H.-B., Li, H.-Y., Lyu, S.-K., Tak, S.-H., Moon, S.-M., and Zhang, Q., “Optimal Design of a Tilling Machine Reduction Gearbox Using Matlab,” International Journal of Precision Engineering and Manufacturing, Vol. 10, No. 2, pp. 63–66, 2009.
Ren, F., Qin, D., Lim, T.C., and Lyu, S., “Study on Dynamic Characteristics and Load Sharing of a Herringbone Planetary Gear with Manufacturing Errors,” International Journal of Precision Engineering and Manufacturing, Vol. 15, No. 9, pp. 1925–1934, 2014.
Khoualdia, T., Hadjadj, A. E., Bouacha, K., and Abdeslam, D. O., “Multi-Objective Optimization of Ann Fault Diagnosis Model for Rotating Machinery Using Grey Rational Analysis in Taguchi Method,” The International Journal of Advanced Manufacturing Technology, Vol. 89, Nos. 9–12, pp. 3009–3020, 2017.
Alam, M. N. H. Z., Hossain, F., Vale, A., and Kouzani, A., “Design and Fabrication of a 3D Printed Miniature Pump for Integrated Microfluidic Applications,” International Journal of Precision Engineering and Manufacturing, Vol. 18, No. 9, pp. 1287–1296, 2017.
Al-Hamadani, H., An, T., King, M., and Long, H., “System Dynamic Modelling of three Different Wind Turbine Gearbox Designs under Transient Loading Conditions,” International Journal of Precision Engineering and Manufacturing, Vol. 18, No. 11, pp. 1659–1668, 2017.
Baek, J. H., “The Change of the Influence of Backlash Ratio according to the Change of Motor Input Voltage,” Journal of Korean Society for Precision Engineering, Vol. 34, No. 11, pp. 771–779, 2017.
Cho, C.-I. and Ahn, H.-J., “Control Performance Test of an Electrically-controlled Variable Valve Timing System using Servo Motors,” Journal of Korean Society for Precision Engineering, Vol. 34, No. 6, pp. 397–403, 2017.
Huang, T.-H., Jiang, C.-P., and Grechnikov, F. V., “Effect of Grain Size on Mechanical Revolution of Pure Titanium and Die Cavity Filling Rate in Hot Squeezing Mini Spur-Gear Forming Process,” International Journal of Precision Engineering and Manufacturing, Vol. 18, No. 10, pp. 1371–1377, 2017.
Kang, J.-H. and Lee, H.-W., “Study on the Design Parameters of a Low Speed Coupling of a Wind Turbine,” International Journal of Precision Engineering and Manufacturing, Vol. 18, No. 5, pp. 721–727, 2017.
Kim, T., Seol, J. W., Hu, S. H., and Baek, J. H., “The Effect of Micropeening to Improve the Fatigue Characteristic of Reduction Gear of Manned and Unmanned Aircraft,” Journal of Korean Society for Precision Engineering, Vol. 34, No. 9, pp. 603–608, 2017.
Kodeeswaran, M., Verma, A., Suresh, R., and Senthilvelan, S., “Bi-Directional and Uni-Directional Bending Fatigue Performance of Unreinforced and Carbon Fiber Reinforced Polyamide 66 Spur Gears,” International Journal of Precision Engineering and Manufacturing, Vol. 17, No. 8, pp. 1025–1033, 2016.
Kwak, H.-S., Li, S.-H., and Kim, C., “Performance Improvement of an Oil Pump: Design of Port Assembled with Gerotor (2-Ellipses-Combined Lobe),” International Journal of Precision Engineering and Manufacturing, Vol. 17, No. 8, pp. 1017–1024, 2016.
Lee, J. Wm, Ham, Y. S., and Seok, C. S., “A Study on the Accelerated Life Test of Axle Bearing for Railway Vehicles using Rotational Speed-temperature Variation Curve,” Journal of the Korean Society for Precision Engineering, Vol. 34, No. 12, pp. 867–872, 2017.
Liang, D., Chen, B., Peng, S., Hua, C., and Liao, R., “Deviation Calculation and Analysis of Tooth Surfaces of Conjugate-Curve Gear Drive,” International Journal of Precision Engineering and Manufacturing, Vol. 18, No. 5, pp. 689–696, 2017.
Lim, C. W., “Design and Manufacture of Small-Scale Wind Turbine Simulator to Emulate Torque Response of MW Wind Turbine,” International Journal of Precision Engineering and Manufacturing-Green Technology, Vol. 4, No. 4, pp. 409–418, 2017.
Mertens, A. J. and Senthilvelan, S., “Durability of Polymer Gear-Paired with Steel Gear Manufactured by Wire Cut Electric Discharge Machining and Hobbing,” International Journal of Precision Engineering and Manufacturing, Vol. 17, No. 2, pp. 181–188, 2016.
Park, J. S., Kim, K. H., Kim, L.-S., and Lyu, S. K., “A Study on Design of Cycloid Reducer for Remote Weapons Systems,” Journal of the Korean Society for Precision Engineering, Vol. 34, No. 6, pp. 405–410, 2017.
Park, M. S., Lee, J. S., Kim, D. Y., and Lee, E. S., “Design and Performance Test of a Rotary Actuator for Side Tilting Excavator Bucket,” Journal of the Korean Society for Precision Engineering, Vol. 34, No. 1, pp. 47–51, 2017.
Yang, X., Cao, H.-J., Chen, Y.-P., Zhu, L.-B., and Li, B.-J., “An Analytical Model of Chip Heat-Carrying Capacity for High-Speed Dry Hobbing Based on 3D Chip Geometry,” International Journal of Precision Engineering and Manufacturing, Vol. 18, No. 2, pp. 245–256, 2017.
Yang, Y., Fan, H., and Ma, P.-C., “Research on Dynamic Characteristics for Longwall Shearer Cutting Transmission System with Varying Cutting Speed,” International Journal of Precision Engineering and Manufacturing, Vol. 18, No. 8, pp. 1131–1138, 2017.
Zong, C.-F., Ren, M.-H., Wan, U., Chen, T., and Bai, Y.-B., “Optimization of Macro-Geometric Parameters of Helical Gears of Transmissions to Reduce Vibration,” Jilin Daxue Xuebao (Gongxueban), Vol. 46, No. 6, pp. 1772–1779, 2016.
Kim, J. G., Lee, G. H., Park, Y. J., Nam, Y. Y., and Chong, T. H., “Study of Load Distribution and Sharing Characteristics of Planetary Geartrain for Wind Turbines,” Applied Mechanics and Materials, Vol. 86, pp. 674–679, 2011.
Noh, S. Y., Kim, L. S., Cho, S. H., and Lyu, S. K., “Study on the Tooth Micro-geometry Optimization of Planetary Gear for Drive Reducer,” Journal of the Korean Society for Precision Engineering, Vol. 34, No. 6, pp. 371–376, 2017.
Jeon, M. H., Joen, N., Kim, L. S., Cho, S. H., and Lyu, S. K., “A Study on the Gear Tooth Micro-Geometry Optimization of Angle Drive Unit,” Journal of the Korean Society for Precision Engineering, Vol. 35, No. 5, pp. 473–478, 2018.
Ni, G., Zhu, C., Song, C., Du, X., and Zhou, Y., “Tooth Contact Analysis of Crossed Beveloid Gear Transmission with Parabolic Modification,” Mechanism and Machine Theory, Vol. 113, pp. 40–52, 2017.
Wu, Y.-R. and Tran, V.-T., “Transmission and Load Analysis for a Crowned Helical Gear Pair with Twist-Free Tooth Flanks Generated by an External Gear Honing Machine,” Mechanism and Machine Theory, Vol. 98, pp. 36–47, 2016.
Lee, K. H., Lee, G. H., Bae, I. H., and Chong, T. H., “Optimum Design of Hypoid Gear Considering the Volume,” Proc. of Korean Society of Machine Tool Engineers Spring Conference, pp. 495–500, 2007.
Bae, I. H., Chong, T. H., Lee, G. H., Lee, K. H., Park, S. H., and Kim, Y. S., “Optimal Design of Hypoid Gears,” Proc. of the Korean Society of Manufacturing Technology Engineers Conference, pp. 421–425, 2006.
Zhang, Q., Zhang, J., Zhu, Z. G., Wang, Z. R., Xu, Z.-z., and Lyu, S. K., “Study on the Transmission Error Prediction for a Spur Gear Pair,” Journal of the Korean Society for Precision Engineering, Vol. 33, No. 2, pp. 109–114, 2016.
Kim, J. G., Park, Y., Lee, G. H., Oh, J. Y., and Kim, Y. J., “A Study on the Load Sharing among Planet Gears According to the Phase of Carrier Pinhole Position Error in the Planetary Gearbox,” Journal of the Korean Society for Precision Engineering, Vol. 34, No. 6, pp. 377–382, 2017.
Chong, T. H., Yang, W. Y., and Lee, K. H., “An Optimum Design of Planetary Gear Considering the Volume,” Proc. of Korean Society of Manufacturing Technology Engineering Autumn Conference, pp. 369–373, 2009.
Kim, J.-G., Park, Y.-J., Lee, S.-D., Oh, J.-y., Kim, J.-H., and Lee, G.-H., “Influence of the Carrier Pinhole Position Errors on the Load Sharing of a Planetary Gear Train,” International Journal of Precision Engineering and Manufacturing, Vol. 19, No. 4, pp. 537–543, 2018.
Park, Y.-J., Kim, J.-G., Lee, G.-H., and Shim, S. B., “Load Sharing and Distributed on the Gear Flank of Wind Turbine Planetary Gearbox,” Journal of Mechanical Science and Technology, Vol. 29, No. 1, pp. 309–316, 2015.
Radzevich, S. P., “Dudley’s Handbook of Practical Gear Design and Manufacture,” CRC Press, 2012.
Park, Y.-J., Kim, J.-G., Lee, G.-H., Kim, Y.-J., and Oh, J.-Y., “Effects of Bearing Characteristics on Load Distribution and Sharing of Pitch Reducer for Wind Turbine,” International Journal of Precision Engineering and Manufacturing-Green Technology, Vol. 3, No. 1, pp. 55–65, 2016.
Bozca, M., “Torsional Vibration Model Based Optimization of Gearbox Geometric Design Parameters to Reduce Rattle Noise in an Automotive Transmission,” Mechanism and Machine Theory, Vol. 45, No. 11, pp. 1583–1598, 2010.
Kim, S. K., Sung, G., Gwon, J. G., and Kim, J. H., “Controlled Phase Separation in Flexible Polyurethane Foams with Diethanolamine Cross-Linker for Improved Sound Absorption Efficiency,” International Journal of Precision Engineering and Manufacturing-Green Technology, Vol. 3, No. 4, pp. 367–373, 2016.
Dion, J.-L., Le Moyne, S., Chevallier, G., and Sebbah, H., “Gear Impacts and Idle Gear Noise: Experimental Study and Non-Linear Dynamic Model,” Mechanical Systems and Signal Processing, Vol. 23, No. 8, pp. 2608–2628, 2009.
Kim, Y., Park, J., Lee, N.-K., and Yoon, J., “Profile Design of Loop-Type Blade for Small Wind Turbine,” International Journal of Precision Engineering and Manufacturing-Green Technology, Vol. 4, No. 4, pp. 387–392, 2017.
Smith, J. D., “Gear Noise and Vibration,” CRC Press, 2003.
Theodossiades, S., Tangasawi, O., and Rahnejat, H., “Multi-Physics Approach for Analysis of Transmission Rattle,” in: Tribology and Dynamics of Engine and Powertrain, Rahnejat, H., (Ed.), Elsevier, pp. 878–913, 2010.
Welbourn, D., “Fundamental Knowledge of Gear Noise: A Survey,” 1979.
Houser, D. R., Harianto, J., and Ueda, Y., “Determining the Source of Gear Whine Noise,” Gear Solutions, 2004. https://doi.org/gearsolutions.com/features/determining-the-source-of-gear-whine-noise/(Accessed 27 SEP 2018)
Lee, K.-H., Park, J.-H., Lee, G.-H., and Nam, Y.-Y., “Study on Design Characteristics of Gearbox for Wind Turbine Considering the Type of Gear Train,” Proc. of the Korean Society for New and Renewable Energy Conference, pp. 387–390, 2007.
ANSI/AGMA 6123-B06, “Design Manual for Enclosed Epicyclic Gear Drives,” 2006.
Lee, K., Lee, G., Kim, D., and Cho, J., “Strength Characteristics Analysis for Addendum Modification of a Gear Using Special-Purpose Vehicle,” Proc. of the Korean Society of Automotive Engineers Conference, pp. 1032–1037, 2007.
Lee, K.-H., Lee, G.-H., Bae, I.-H., and Chong, T.-H., “An Optimum Design Method of Hypoid Gear by Minimizing Volume,” Transactions of the Korean Society of Machine Tool Engineers, Vol. 16, No. 6, pp. 55–61, 2007.
Kognole, S., “Optimizing the Geometric Parameters of New Gear Pair Using Existing Gear Pairs,” SAE Technical Paper, No. 2014-01-1770, 2014.
Langhart, J. and Kivelä, R., “Gears in Drive Engineering Optimization of Bevel Gears,” Konstruktion, Nos. 11–12, pp. 34–37, 2010.
Lasova, V., Bernardin, p., and Kronerovq, E., “Comparison of Capabilities of Finite Element Method and Specialized Software Programs in Evaluation of Gears,” MM (Modern Machinery) Science Journal, Vol. 6, pp. 610–612, 2015.
Rajagopal, M., Kumar, S., and Rao, N., “Minimizing Tooth Mesh Misalignment in Heavy Duty Tractor Transmission,” SAE Technical Paper, No. 2016-01-8069, 2016.
Rajagopal, M., “Conceptual Design Challenges and Solutions in Power Shuttle Transmission Development for Legacy Tractors,” SAE Technical Paper, No. 2018-01-0394, 2018.
Tsai, S., Ye, S., Yu, Y., and Tseng, J., “Design and Analysis of the Planetary Gear Drive with Flexible Pins for Wind Turbines,” Proc. of EWEA Conference, Vol. 2, pp.706–715, 2012.
Weis, P., Kučera, Ľ., Pecháč, P., and Močilan, M., “Modal Analysis of Gearbox Housing with Applied Load,” Procedia Engineering, Vol. 192, pp. 953–958, 2017.
Romax Technology Ltd., “Romax Designer Software Manual,” 2003.
Han, J. W., Nam, J. S., Park, Y. J., Lee, G. H., and Nam, Y. Y., “An Experimental Study on the Performance and Fatigue Life of Pitch Bearing for Wind Turbine,” Journal of Mechanical Science and Technology, Vol. 29, No. 5, pp. 1963–1971, 2015.
Kim, D. C., Kim, K. U., Park, Y. J., and Huh, J. Y., “Analysis of Shifting Performance of Power Shuttle Transmission,” Journal of Terramechanics, Vol. 44, No. 1, pp. 111–122, 2007.
Kim, J. G., Park, Y. J., Lee, G. H., Nam, Y. Y., and Yang, W. Y., “Optimum Design of Pitch Reducer for Wind Turbine Using Genetic Algorithm,” Transactions of the Korean Society of Mechanical Engineers A, Vol. 38, No. 2, pp. 185–192, 2014.
Sigg, H., “Profile and Longitudinal Corrections on Involute Gears,” AGMA, 1965. https://doi.org/artec-machine.com/wp-content/docs/protected/profile_&_longitudinal_corrections_on_involute_gears.pdf (Accessed 27 SEP 2018)
Author information
Authors and Affiliations
Corresponding author
Additional information
Zhen Qin M.Sc. candidate in the Department of Mechanical Engineering, Gyeongsang National University. His research interest is Mechanical System Design.
Yu-Ting Wu Ph.D. candidate in the Department of Mechanical Engineering, Gyeongsang National University. Her research interest is Mechanical System Design.
Sung-Ki Lyu Professor in the Department of Mechanical Engineering, Gyeongsang National University. His research interest is Mechanical System Design.
Rights and permissions
About this article
Cite this article
Qin, Z., Wu, YT. & Lyu, SK. A Review of Recent Advances in Design Optimization of Gearbox. Int. J. Precis. Eng. Manuf. 19, 1753–1762 (2018). https://doi.org/10.1007/s12541-018-0203-z
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12541-018-0203-z