TOPOLOGY OPTIMIZATION BASED DESIGN AND DEVELOPMENT OF SPUR GEAR: OPTIMISATION

This work explores weight reduction in gears through design optimization and advanced manufacturing methods. Gears are widely used in many industrial systems, but their solid internal structure often increases overall system weight and material consumption. The study investigates ways to reduce gear body mass while maintaining the mechanical performance required in practical applications.Instead of changing the material, the research focuses on optimizing the internal material layout using generative design and lattice structures. Generative design, also known as topology optimization, uses mathematical methods to distribute material efficiently within a defined design space based on loads, boundary conditions, and constraints. In parallel, lattice structures inspired by biological patterns employ repeating unit cells to reduce weight while maintaining structural integrity.Static analysis of a helical gear with a uniform lattice structure helps determine suitable beam thickness and optimize the lattice configuration. The complete design and analysis process is carried out using NX CAD software. The optimized models are then fabricated through FDM-based additive manufacturing.