A new method to predict the service performance of lightweight gear incorporating lattice structures

Topology optimized, Lattice-structured, and Topology optimized-lattice (Hybrid-structured) gears were designed to investigate the influence of web geometric structure on the gear service performance, such as contact stress, bending stress and transmission error. The gear stress distributions and transmission errors were simulated using finite element analysis (FEA). The gear samples were manufactured through the additive manufacturing (AM) equipment. An AHP-based normalized scoring system was proposed to quantitatively evaluate the influence of web structure on gear service performance, with due consideration given to weight reduction. Additionally, the stress responses of Hybrid-structured gears under varying topological array architectures were analyzed by altering the number of topological arrays. Results indicate that the hybrid-structured gear achieves an optimal balance in service performance. Compared to normal gears, the Hybrid-structured gear achieved a 7.6% weight reduction while increasing transmission error by only 4.5%, and the tooth contact stress remains relatively constant.