US Patent

US010865867B2
( 12 ) Anand
Unitedet alStates Patent ( 10) Patent No .: US 10,865,867 B2
. (45 ) Date of Patent : Dec. 15 , 2020
( 54 ) LIGHTWEIGHT TORQUE TRANSMISSION ( 58 ) Field of Classification Search

GEAR CPC F16H 55/06 ; F16H 55/02 ; F16H 55/17 ;
F16H 2055/065 ; F16H 2055/176
(71 ) Applicant: Eaton Intelligent Power Limited , See application file for complete search history .
Dublin ( IE ) ( 56 ) References Cited
( 72 ) Inventors: Anuj Anand , Pune ( IN) ; Hari Prasad U.S. PATENT DOCUMENTS
Konka , Pune (IN) ; Peter James Fritz ,
Williamston , MI (US ) 2,064,144 A 12/1936 Benge
2,064,723 A * 12/1936 Benge F16H 55/06
( 73 ) Assignee : Eaton Intelligent Power Limited , 74/445
Dublin ( IE ) ( Continued )
( * ) Notice: Subject to any disclaimer, the term of this FOREIGN PATENT DOCUMENTS
patent is extended or adjusted under 35 CN 101078432 11/2007
U.S.C. 154 ( b ) by 187 days . DE 102007062349 6/2009
EP 1143165 10/2001
( 21 ) Appl . No .: 15 /771,601
OTHER PUBLICATIONS
( 22 ) PCT Filed : Nov. 7, 2016
Krantz, T.L et al . , “ Increased Surface Fatigue Lives of Spur Gears
(86 ) PCT No .: PCT/US2016/ 060796 by Application of a Coating ” , 2003 , 16pgs , https://ntrs.nasa.gov/
$ 371 ( c )( 1 ), archive /nasa /casi.ntrs.gov/20030068247.pdf.
( 2 ) Date : Apr. 27, 2018 Primary Examiner Thomas C Diaz
(87 ) PCT Pub . No .: WO2017/079730 (74 ) Attorney, Agent, or Firm - Dierker & Kavanaugh,
P.C.
PCT Pub . Date : May 11 , 2017 ( 57 ) ABSTRACT
(65 ) Prior Publication Data A torque transmitting gear includes a steel toothed annular
US 2018/0320772 A1 Nov. 8 , 2018
flange having gear teeth defined on a periphery of the steel
toothed annular flange. A steel hub is coaxially aligned with
( 30 ) Foreign Application Priority Data the steel toothed annular flange. A web is formed from a web
material having a density less than or equal to 3.0 grams per
Nov. 7 , 2015 ( IN ) 3645 /DEL/2015 cubic centimeter. The web is fixedly attached to the toothed
annular flange and to the hub for rotation together with the
( 51 ) Int . Ci. toothed annular flange and the hub . The gear is to opera
F16H 55/06 ( 2006.01 ) tively transmit a torque of at least 500 Newton Meters for at
F16H 55/02 ( 2006.01 ) least 6 million revolutions of the gear. An overall mass of the
F16H 55/17 ( 2006.01 ) gear is less than two - thirds of an overall mass of a same
( 52 ) U.S. CI . sized all steel gear having a solid steel web with a solid steel
CPC web thickness at least one - third of a face width of the
F16H 55/06 (2013.01 ) ; F16H 55/02 toothed annular flange.
(2013.01 ) ; F16H 55/17 (2013.01 ) ; F16H
2055/065 (2013.01 ) ; F16H 2055/176 (2013.01 ) 22 Claims , 16 Drawing Sheets
50 STRUCTURAL
OPTIMIZATION
70 80 90
TOPOLOGY TOPOGRAPHY SHAPE SIZE

OPTIMIZATION VY
OPTIMIZATION OPTIMIZATION OPTIMIZATION
USED IN INITIAL DESIGN 3 USED IN FINAL PHASE TO 0
PHASE OR CONCEPT PHASE FINE TUNE THE DESIGN

-65 85
US 10,865,867 B2
Page 2
( 56 ) References Cited
U.S. PATENT DOCUMENTS
2,839,943 A * 6/1958 Hausmann F16H 55/06
74/445
3,200,665 A 8/1965 Wells
5,271,287 A 12/1993 Wadleigh
8,595,934 B2 * 12/2013 Derse F16H 55/14
29/ 893.37
8,795,569 B2 * 8/2014 Oberle F16H 55/06
264/261
8,949,087 B2 2/2015 Oliverius et al .
2002/0043124 A1 * 4/2002 Shiga B29C 45/16
74/434
2006/0053917 A1 3/2006 Asari et al .
2009/0282939 Al * 11/2009 Rogowski F16H 55/06
74 /424.5
2013/0228028 A1 9/2013 Kim et al .
2018/0017150 A1 * 1/2018 Leupold B22F 7/002
* cited by examiner
U.S. Patent Dec. 15 , 2020 Sheet 1 of 16 US 10,865,867 B2
50 STRUCTURAL
OPTIMIZATION
70 80 90
TOPOLOGY TOPOGRAPHY SHAPE SIZE

OPTIMIZATION
**** ***** **** ********
OPTIMIZATION
*** ***** ***** ***
OPTIMIZATION
pit * * ** * *** ***** ***
OPTIMIZATION
8
USED IN INITIAL DESIGN USED IN FINAL PHASE TO
1
PHASE OR CONCEPT PHASE 0
FINE TUNE THE DESIGN
-65 85
FIG . 1
100
105
110
INPUTTING A FINITE ELEMENT MODEL OF AN INITIAL STRUCTURAL DESIGN VIAA USER INTERFACE
DEFINING DESIGN AND NON - DESIGN SPACE ON THE INITIAL STRUCTURAL DESIGN 120
SETTING UP TOPOLOGY OPTIMIZATION PARAMETERS
ITERATIVELY OPTIMIZING TOPOLOGY VARIATIONS FROM THE INITIAL STRUCTURAL DESIGN BY

VARYING THE TOPOLOGY OPTIMIZATION PARAMETERS IN A COMPUTER SIMULATOR RUNNING
A COMPUTER SIMULATION UNTIL TOPOLOGY OPTIMIZATION CRITERIA ARE SATISFIED TO
GENERATE A TOPOLOGY OPTIMIZED DESIGN
STORING THE TOPOLOGY OPTIMIZED DESIGN INAFIRST THREE DIMENSIONAL MODELING FORMAT;
ITERATIVELY OPTIMIZING GEOMETRY VARIATIONS FROM THE TOPOLOGY OPTIMIZED DESIGN

BY VARYING GEOMETRIC OPTIMIZATION PARAMETERS OF EACH GEOMETRY DESIGN ITERATION 160
IN THE COMPUTER SIMULATOR RUNNING THE COMPUTER SIMULATION AND EVALUATING
GEOMETRY OPTIMIZATION CRITERIA UNTIL GEOMETRY OPTIMIZATION TARGETS ARE SATISFIED
TO GENERATE AGEOMETRY OPTIMIZED DESIGN ;
STORING THE GEOMETRY OPTIMIZED DESIGN IN ASECOND THREE DIMENSIONAL MODELING FORMAT:
GENERATING A HARDWARE PROTOTYPE ACCORDING TO THE GEOMETRY OPTIMIZED DESIGN
FIG . 2
112
3
}
3
WHEREN: 3
! THE INITIAL STRUCTURAL DESIGN INCLUDES A FIRST MATERIAL AND A SECOND MATERIAL; 3
THE FIRST MATERIAL AND THE SECOND MATERIAL ARE DISSIMILAR ;AND
THE FIRST MATERIAL IS JOINED TO THE SECOND MATERIAL THEREBY FORMING A JOINT 3
3
3
*
113 $
3
3
1
3
E
1
3 11 j
www am= = 3 1 &
************** 3
&
WHEREIN THE JOINT IS A MECHANICAL INTERFERENCE - BASED JOINT 1
3
3
E
1
3 145 1
}
11
MM WWWWWWMMMWWWWWMMMWW ning
3
1 WHEREIN THE COMPUTER SIMULATION INCLUDES : 3 E
1
9
AN AUGMENTED LAGRANGIAN CONTACT ALGORITHM TO DEFINE THE :

B
1 FRICTIONAL CONTACT BETWEEN THE FIRST MATERIAL AND THE SECOND 3
3
3
B 1
1
1
MATERIAL AT THE INTERFERENCE-BASED JOINT: AND 3
3
E
AFINITE ELEMENT METHOD ALGORITHM TO CALCULATE STRESSE 3 :)

:
AND STRAINS UNDER INTERNAL AND EXTERNAL LOADS 3

:)
1
&
E 1
1
.
WWMWWWWWWWWWWWWW MM wwww WMMWWWWWW
&
1
1
WHEREIN : &
1
THE FIRST MATERIAL IS BONDED TO THE SECOND MATERIAL BYAN
ADHESIVE DISPOSED BETWEEN THE FIRST MATERIAL AND THE SECOND MATERIAL,
1
THEREBY FORMING THE JOINT; AND &
1
1
THE JOINT IS AN ADHESIVELY BONDED JOINT 1
8 3
6
$ B
AN DE
FIG . 3
B 115
3
WWW CA * * * * * ** W 1K w * * 1 t? * * ** *** **** *
31
WHEREIN $
A COHESIVE ZONE METHOD IS APPLIED TO MODEL COHESIVE ZONE ELEMENTS OF THE

ADHESIVELY BONDED JOINT; AND
1 AFINITE ELEMENT METHOD ALGORITHM INCLUDING A COHESIVE ZONE MODULE CALCULATES 3
1
1
STRESSES AND STRAINS UNDER INTERNAL AND EXTERNAL LOADS A na www W M W *
8
116
w wWw wWMWMMWWMW WMMMWWW
1 WHEREIN THE COHESIVE ZONE METHOD INCLUDES :

DETERMINING TRACTION SEPARATION LAWS FORA MODEI CRACK SEPARATION AND A MODE |
1 CRACK SEPARATION OF THE FIRST MATERIAL AND THE SECOND MATERIAL BONDED BY THE ADHESIVE ; 3
DEFINING THE COHESIVE ZONE ELEMENTS IN A FINITE ELEMENT MODEL , WHEREIN DEFINING 3
THE COHESIVE ZONE ELEMENTS INCLUDES GENERATINGA MESH FOR THE COHESIVE ZONE ELEMENTS
AND APPLYING THE TRACTION SEPARATION LAWS AS ELEMENTAL PROPERTIES OF THE COHESIVE ZONE 3
ELEMENTS ; AND 3
}
EXECUTING THE FINITE ELEMENT METHOD ALGORITHM INCLUDING THE COHESIVE ZONE 3
1
MODULE Wwwwwwwwwwwwww www mm mw w w w w w w w w w w w w w
$
FIG . 4
1
wwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwwww * ** * * * * ** * * * * * *
3
WHEREIN THE DETERMINING TRACTION SEPARATION LAWS INCLUDES EMPIRICALLY DETERMINING THE
1
1
TRACTION SEPARATION LAWS FROMADOUBLE CANTILEVER BEAM TEST TO DETERMINE THE TRACTION
SEPARATION LAW FOR THE MODE I CRACK SEPARATION AND A LAP SHEAR TEST TO DETERMINE THE
TRACTION SEPARATION LAW FOR THE MODE IL CRACK SEPARATION
A ** .
118
12 * * * * * * * * * * * * * * * * * * * * * * ** **** ********
}
WHEREIN ; $
THE DOUBLE CANTILEVER BEAM TEST METHOD IS DEFINED BY ASTM D5528 ; }
AND 3
3
f
THE LAP SHEAR TEST METHOD IS DEFINED BY ASTM D5868 }
WWW WWW
FIG . 5
142
6
y son un YN
3
3
WHEREIN VARYING THE TOPOLOGY OPTIMIZATION PARAMETERS INCLUDES :
DETERMINING AN ELEMENTAL DENSITY FOR EACH ELEMENT OF THE FINITE ELEMENT MODEL ;
1
DETERMININGA MINIMUM DENSITY THRESHOLD BASED ON A WEIGHT SAVINGS PERCENTAGE
} TARGET AND A MAPPING OF THE ELEMENTAL DENSITY ON THE FINITE ELEMENT MODEL ;
1 SETTING THE ELEMENTAL DENSITY TO ZERO FOR EACH OF THE ELEMENTS OF THE FINITE
3
ELEMENT MODEL HAVING AN ELEMENTAL DENSITY LESS THAN A MINIMUM DENSITY THRESHOLD ; AND B
1
ASSIGNING THE ELEMENTAL DENSITY TO 1 FOR EACH OF THE ELEMENTS OF THE FINITE ELEMENT
MODEL HAVING AN ELEMENTAL DENSITY GREATER THAN OR EQUAL TO THE MINIMUM DENSITY THRESHOLD ;
3 AND 1
VARYING THE TOPOLOGY OPTIMIZATION PARAMETERS IN THE ELEMENTS OF THE FINITE ELEMENT
1
3 MODEL HAVING THE ELEMENTAL DENSITY ASSIGNED TO 1
FIG . 6
-- 143
8
WHEREIN THE EVALUATING GEOMETRY OPTIMIZATION CRITERIA INCLUDES :
DEFINING RELATIONSHIPS BETWEEN AN OVERALL COST AND THE GEOMETRIC OPTIMIZATION 1
PARAMETERS, AND
wwmmy
CALCULATING THE OVERALL COST FOR EACH GEOMETRY DESIGN ITERATION 3
wwwmmmm WWMWWWWMMMW
$
E
1
WWWWWMMMWWWWWWMWWWW MM WWWWW WMMMMWWWWWMM
1
3
WHEREIN THE OVERALL COST INCLUDES A MATERIAL COST 3
AND A MANUFACTURING COST

* ** ** * * * * * * S * :
WHEREIN THE GEOMETRIC OPTIMIZATION PARAMETERS INCLUDE :

3
$ AQUANTITY OF A VARIABLE DESIGN FEATURE; 146
ASIZE OF THE VARIABLE DESIGN FEATURE ; OR
A SHAPE OF THE VARIABLE DESIGN FEATURE
wwmmmmwwwmmmm WWWWWWWWWWWWWWWWWWWWWW
www
w w w w w w w w w w w w w w w w Www * w w w w w w w wWwwWw w w w w w w w w w w w M MV
3
WHEREIN THE VARIABLE DESIGN FEATURE INCLUDES A HOLE , A FILLET, OR A CHAMFER 3
FIG . 7
20 Y
20 24
23
25
mah
23 22 X
22
FIG . 8 27
FIG . 9
SEE FIG . 10B * donToa NOW ONUDUM AD ORODOAZED MU Cui
12
FIG . 10A FIG . 10B
28 28
FIG . 11
AI SYMMETRY REGION
BSYMMETRY REGION 2
32
FIG . 12
36
22
23
95 39
asper
-35 34 Ic1
162 11
WWW WWE MM Www MA
Pc 1
PC
FIG . 13 FIG . 14
CRACK TIP
CRACK
COHESIVE ZONE ELEMENTS
FIG . 15
WFEAMCZMOIDTEHL 43
ZONE
E(
CZE
)
LEMENTS42 ECLZMENMTS
CDOEHFISNVEG
16
.
FIG
0
TGERNACIONG LSEPARTWION 41
STERPACION r
WU
TEXPRISMENTAL 40 SEXPRTIMEUNPAL
? • 79
98
FIG . 17
91
87
89
7
wwwwwwww
91
FIG . 18
100 '
WWWWW WWWWMWWWWWWM wwwwwwmmwwwwwwwwwwwwwwwwwwwwmmwww

:
3
PHASE 11
INITIAL DESIGN 0
11
1
11
:)
3 DEFINE DESIGN AND NON DESIGN 51
SPACE 11
.
3
3
SET UP TOPOLOGY OPTIMIZATION .
PARAMETERS AND SUBMIT RUN 0

.
11
1
ALL 52
NO 11
3
CONSTRAINTS 11
2
SATISFIED ? 1
.
0
YES PHASE 11
1
53 2
3
E EXTRACT GEOMETRY IN THREE .
DIMENSIONAL MODELING FORMAT :
.
1:
3 :
3
3
INTERPRET AND REDESIGN 54
11
GEOMETRY :
1:1
M M M Y YY XXX w w w w w w w w w w w w w w Www X X X W . w Www X X X
3
11 PHASE 11
SIZE AND PERFORM FE SIMULATION ON 3

1 SHAPE RESTRUCTURED GEOMETRY 1:1
33
OPTIMIZATION :
11
.
.
.
3 NO OVERALL 1:1
:
3
3
PERFORMANCE :
SATISFIED ?
0
1
3
YES
23 .
TASK COMPLETED :
FIG . 19
NON DESIGN SPACE 20

DESIGN
SPACE
30
29
-31
FIG . 20
62
-45
FIG . 21
RECREATED GEOMETRY AFTER

TOPOLOGY OPTIMIZATION
SET UP OPTIMIZATION PARAMETERS

: FILLET RADIUS , CHAMFER AND THICKNESS
PREPARE MODEL SET UP WITH

DIFFERENT DESIGN VARIABLES OR
PARAMETERS
SUBMIT RUNS AND CALCULATE

RESPECTIVE CONSTRAINTS ,
RESPONSE AND OBJECTIVE
FUNCTION VALUES FOR EACH SET UP
NO ALL
CONSTRAINTS
SATISFIED
YES
OBTAIN OPTIMIZED VALUES FOR
EACH DESIGN VARIABLE
OR PARAMETERS
FIG . 22
62
FIG . 23
18 13
11
w 18
18
56 Mara w 12
14
-15
18
wymiana
11
55 16
13 17
18 w 18 12
46
FIG . 24A FIG . 24B
81 81 '
-82
82
83 83
FIG . 25 FIG . 26
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61
92
13
60
57 66
49 58
64
-68
86
78
67
mahir
13
71 72
76
11
A
75
FIG . 27
19
19
21 Wanneermen ou nos nos a
19
TITIL Anetan o ano ano anode ao messo in
16
opontendwe 19
21
FIG . 28
US 10,865,867 B2
1 2
LIGHTWEIGHT TORQUE TRANSMISSION FIG . 8 is a semi- schematic cross - sectional view of a two
GEAR layer multilayer tube constructed from dissimilar materials
in an example of the present disclosure;
CROSS - REFERENCE TO RELATED FIG . 9 is a semi- schematic cross - sectional view of a
APPLICATIONS 5 single quadrant of the multilayer tube depicted in FIG . 8 ;
FIG . 10A is a cross - sectional view depicting finite
This application claims the benefit of Indian Provisional element mesh generated on the cross - section depicted in
Application No. 3645 / DEL/2015 , filed Nov. 7 , 2015 , the FIG . 9 ;
contents of which are incorporated herein by reference . 10 theFIG . 10B is a cross - sectional detailed view of a portion of
finite element mesh depicted in FIG . 10A ;
BACKGROUND FIG . 11 is a cross -sectional view depicting the single
quadrant of the multilayer tube depicted in FIG . 9 with
Efficient and lighter components /systems are applied to contact edges at the indicated locations ;
FIG . 12 is a cross - sectional view depicting the single
consumer and industrial products across the spectrum of 15 quadrant
human endeavor. Vehicles that include lightweight devices symmetricofboundary the multilayer tube depicted in FIG . 9 defining
conditions for the finite element model ;
can reduce energy consumption and reduce engine emis
sions . Industrial, automotive, and aviation business sectors pressure on the outer cylindercross
FIG . 13 is a schematic
of
-sectional view depicting
the multilayer tube depicted
place an emphasis on the design , procurement and produc in FIG . 8 ;
tion of lighter and more efficient systems . The combination 20 FIG . 14 is a schematic cross - sectional view depicting
of composite materials with other materials in structural pressure on the inner cylinder of the multilayer tube depicted
( load -bearing ) components has contributed to lighter and in FIG . 8 ;
more efficient systems . FIG . 15 is a schematic diagram depicting examples of
Aluminum is currently one of the most used lightweight cohesive zone elements according to the present disclosure ;
materials in aviation . Many aircraft structural parts are made 25 FIG . 16 is a schematic diagram depicting examples of
from aluminum alloys . Some wind turbine manufacturers steps in the cohesive zone method as disclosed herein ;
use glass fiber and carbon fiber composites as structural FIG . 17 is a schematic illustration of a test setup for a
materials for wind turbine blades . Advanced plastics ( e.g. , Lap - Shear Test (Mode II ) ;
for automotive vehicle fenders and doors ) and improved FIG . 18 is a schematic illustration of a test setup for a
steel alloys (e.g. , for automotive vehicle chassis compo 30 double cantilever beam test (Mode I ) ;
nents ) are used to reduce weight in automobiles . FIG . 19 is a flow chart representing a method that
combines topology optimization with shape and size opti
SUMMARY mization as disclosed herein ;
FIG . 20 is a cross - sectional view of a 3 layer multilayer
A gear for transmitting torque includes a steel toothed 35 tube;
annular flange having gear teeth defined on a periphery of FIG . 21 is a grayscale contour plot of a finite element
the steel toothed annular flange. The gear has a steel hub elementaldepicting
model
density ;
void or hole locations that influence
coaxially aligned with the steel toothed annular flange. The FIG . 22 is a flow chart depicting a work flow of a size and
gear further includes a web formed from a web material 40 shape optimization process ;
having a density less than or equal to 3.0 grams per cubic
centimeter ( g / cm ° ). The web is fixedly attached to the steel model .depicting
FIG 23 is a grayscale contour plot of a finite element
the results of the second example after the
toothed annular flange and to the steel hub for rotation geometry was refined considering manufacturing constraints
together with the steel toothed annular flange and the steel and applying the size and shape optimization process
hub. The gear is to operatively transmit a torque of at least 45 according to the present disclosure ;
500 Newton Meters (N m) for at least 6 million revolutions FIG . 24A is a semi- schematic front view depicting an
of the gear. An overall mass of the gear is less than example of a gear according to the present disclosure ;
two - thirds of an overall mass of a same- sized all steel gear FIG . 24B is a semi- schematic side view depicting the
having a solid steel web with a solid steel web thickness at example of the gear depicted in FIG . 24A according to the
least one - third of a face width of the steel toothed annular 50 present disclosure;
flange. FIG . 25 is a front view photograph of a gear with a round
annular core and shrink fit joints designed using conven
BRIEF DESCRIPTION OF THE DRAWINGS tional methods;
FIG . 26 is a front view photograph of a gear with an oval
Features and advantages of examples of the present 55 annular core and shrink fit joints designed using conven
disclosure will become apparent by reference to the follow- tional methods;
ing detailed description and drawings, in which like refer- FIG . 27 is a semi-schematic front view depicting an
ence numerals correspond to the same or similar, though example of a gear with solid fiberglass reinforced polymer
perhaps not identical, components. For the sake of brevity, composite web according to the present disclosure ; and
reference numerals or features having a previously described 60 FIG . 28 is a schematic perspective view depicting an
function may or may not be described in connection with example of web material having a plurality of layers of
other drawings in which they appear. fiberglass reinforcement according to the present disclosure .
FIG . 1 is a block diagram that schematically depicts
structural optimization according to the present disclosure; DETAILED DESCRIPTION
FIG . 2 - FIG . 7 together are a flow chart depicting an 65
example of the computer implemented method for designing Combining lighter materials, e.g. , fiberglass, carbon com
a mechanical structure as disclosed herein ; posite , aluminum , magnesium , or plastic with other mate
US 10,865,867 B2
3 4
rials , for example, steel in structural components, mayform method of the present disclosure may not be recognized
dissimilar material joint interfaces. Low functional perfor- when the rotational component is lightly loaded . For
mance of the joint between the dissimilar materials, may example , the existing, slow moving gears of a grandfather
lead to an inability of an otherwise suitable device to meet clock may be for smoothly and accurately converting the
overall performance objectives. For example, galvanic cor- 5 reciprocating motion of a pendulum into rotational motion
rosion at the interface between an aluminum and steel of the clock's hands . The torques experienced by the gears
component may be deleterious to strength , durability and of the grandfather clock may not be particularly large.
appearance of the aluminum and steel component. Further, However, the spur gears , helical gears , shafts and clutches in
differences in coefficients of thermal expansion, modulus of a large truck transmission may experience torques of well
elasticity , strength , and ductility of joined materials may over 5QQ Newton Meters . Existing bi-material gears , for
affect suitability of a device for a particular use . example plastic gears with metal teeth , are used in relatively
Certain techniques may be used to join dissimilar mate- low torque applications and are not durable or reliable in
rials . Typically, welding is not used to join dissimilar metals . applications with torques over 500 N · m .
For example, aluminum is not typically welded to steel . The gear example of the present disclosure gives about a
Mechanical interference based joining techniques (thermal 15 33 % weight reduction compared to the existing steel gear
shrink - fit and mechanical press - fit) may be used for joining that has proven to be reliable and durable in transmissions of
dissimilar metals. Adhesively bonded joints may be used for large trucks. A 33 % weight reduction in the gears of a truck
joining dissimilar metal components and dissimilar non- transmission would translate to about 0.5 percent of the
metal components. weight of the truck , which would yield about 0.2 % improve
The thermal shrink - fit process applies the phenomenon of 20 ment in the fuel efficiency. The method of the present
material expansion and contraction during the heating and disclosure was applied to design an example of a gear
cooling cycle respectively, thus achieving mechanical inter- disclosed herein . Working examples of a gear were made
ference without significant assembly force . Thermal shrink- and tested . The example gear was far superior to examples
fit based techniques may be used in mechanical assembly of gears designed using more conventional techniques.
and for delicate parts where an application of significant 25 In an example of the present disclosure , a gear for a large
mechanical pressure or force could be deleterious to the truck transmission has a steel toothed flange. The steel
functionality of the final assembly. Thermal shrink - fitting toothed flange has high strength and durability. The highest
may advantageously reduce stresses and residual deforma- loads experienced by the gear are at the surfaces of the steel
tions (e.g. by reducing interference ). Heating for the process teeth , In turn , torsion stresses are spread, and are transmitted
of creating a thermal shrink - fit joint may be by any suitable 30 through larger cross sectional areas of the gear, where
method, including conduction , convection , and induction alternative materials other than steel can be used . One such
heating, among others . material may be a fiber reinforced polymer composite as
press - fit process may , for example, be used in industrial disclosed herein . The stresses may be so low, in certain
production for low - cost and high - throughput manufacturing. locations on the gear, that portions of the gear may be made
A press - fit is a semi-permanent assembly process for joining 35 with holes or voids . The steel, the alternative material, and
two mechanical components. The mechanical components the voids have multiple interactions and concurrencies that
are locked together by friction at the press - fit joint formed are too complex to resolve by existing methods. For
between the mechanical components after forcing the parts example, the optimization of the present disclosure gener
with mechanical interference therebetween, together. ates an optimized design for load -bearing, deformation ,
Adhesive bonding is a material joining process in which 40 durability, joinery, voiding , and cost .
an adhesive, placed between the adhered surfaces, solidifies In an example of the method of the present disclosure ,
to produce an adhesive bond . Adhesive bonding may have where an interface of materials geometery, voids in the
advantages over classical mechanical fastening techniques. interface , voids in the metal , voids in the composite, amount
For example , the application of adhesive bonding may be and thickness of composite and the size , distribution , and
advantageous for improvements in strength -to -weight ratio , 45 contour characteristics of the voids are simultaneously opti
design flexibility, ease of fabrication , ability to join thin and mized to create the most desirable gear for power transmis
dissimilar components, and low manufacturing cost . sion . As disclosed herein , an effective and efficient design
Joining techniques may create residual stresses in a com- can be achieved within user - defined constraints through
ponent which may affect the overall fatigue performance of structural optimization . FIG . 1 is a block diagram that
the component. Accurately predicting the stresses at inter- 50 schematically depicts structural optimization 50 according
faces of dissimilar materials due to the joining technique to the present disclosure . As used herein , structural optimi
may lead to a more rapid development of reliable products. zation 50 may have the following sub -processes: Topology
As disclosed herein , an effective and efficient design can Optimization 60 ; Topography Optimization 70 ; Shape Opti
be achieved within user -defined constraints through struc- mization 80 ; and Size Optimization 90. As indicated by box
tural optimization . The present disclosure provides details of 55 65 and disclosed herein, Topology Optimization 60 and
a computer implemented method for designing a torque Topography Optimization 70 may be applied in a concept
transmitting structure. The present disclosure also includes a phase or initial design phase . As indicated by box 85 and
detailed example of a gear for transmitting torque that was disclosed herein , Shape Optimization 80 and Size Optimi
refined using the method disclosed herein . It is to be zation 90 may be used in a final phase to fine tune the design .
understood that the method of the present disclosure may be 60 Topology optimization 60 is a method that can be used in
applied to any rotational components in a drivetrain includ- very early stages of a design process to determine an optimal
ing shafts, gears , and other components that transmit rota- material layout in a given design space . For example,
tional energy , have mass , and in vehicles , have the capability topology optimization 60 may determine that a multilayer
of transmitting torque at different locations , speeds , and sheet metal structure will have a steel inner layer and an
directions . The present disclosure includes the shafts, gears , 65 aluminum outer layer. Topography optimization 70 is a
and other components designed using the method of the method that, for example, may find the most efficient bead
present disclosure . Some advantages of the devices and layout or bead pattern in sheet metal structures.
US 10,865,867 B2
5 6
Shape optimization 80 is a process that allows changes in dimensional modeling format . ” Non - limiting examples of
the boundary of product geometry. Boundaries are typically the first three dimensional modeling format include .iges and
represented as smooth surfaces in Finite Element Models .stl formats . At box 160 is iteratively optimizing geometry
since irregular boundaries may affect the accuracy of finite variations from the topology optimized design by varying
element analysis. In shape optimization 80 , selected design 5 geometric optimization parameters of each geometry design
variables are varied with multiple iteration until the defined iteration in the computer simulator running the computer
constraints and objective are fulfilled . simulation and evaluating geometry optimization criteria
Size optimization 90 is a process to optimize the structure until geometry optimization targets are satisfied to generate
by changing sizes of the components. In an example of size a geometry optimized design .” At box 170 , is “ storing the
optimization 90 as disclosed herein , the design variables 10 geometry optimized design in a second three dimensional
may be sizes of structural elements such as a diameter of a modeling format. ” Non- limiting examples of the second
rod or a thickness of a beam . three dimensional modeling format include iges and .stl
The following is a mathematical formulation for an opti- formats. The first three dimensional modeling format may be
mization problem : the same , or differ from the second three dimensional
Objective: Minimize W (x ) 15 modeling format . At box 180 is “ generating a hardware
Constraints: h ( x )50 prototype according to the geometry optimized design .”
Design variables : xlowersxsxupper In FIG . 3 , the flowchart connector A indicates the con
W is an objective function , and h is a constraint function . nection between box 105 shown in FIG . 2 and box 112. In
In an example, the objective function and the constraint box 112 , FIG . 3 depicts “ wherein : the initial structural
function may be related to structural performance and x may 20 design includes a first material and a second material; the
represent elemental density. In the second example first material and the second material are dissimilar ; and the
described more fully below, the structural responses that first material is joined to the second material thereby form
were used to define the objective and constraint functions ing a joint . ” At box 113 , is “ wherein the joint is a mechanical
were : volume fraction, compliance, stress, and deformation . interference -based joint.” At box 145 , is “ wherein the com
Minimizing the mass was the key objective of this example 25 puter simulation includes: an Augmented Lagrangian con
of the topology optimization 60 , subjected to stress and tact algorithm to define a frictional contact between the first
displacement constraints, with elemental density as a design material and the second material at the interference - based
variable . joint; and a finite element method algorithm to calculate
FIG . 2 - FIG . 7 together are a flow chart depicting an stresses and strains under internal and external loads."
example of the computer implemented method 100 for 30 FIG . 9 is a detailed view of a quadrant of the cross
designing a mechanical structure as disclosed herein . FIG . 2 sectional view depicted in FIG . 8. The multilayer tube 20
depicts a set of steps shown in box 105 included in the shown in FIG . 8 and FIG . 9 has an outer cylinder 22 made
method 100. A flow chart connector A indicates the connec- from steel having an elastic modulus of about 200 GigaPas
tion between box 105 and box 112 shown in FIG . 3. Dashed cals (GPa) and a Poisson's ratio of about 0.27 . The outer
lines in the flow chart of FIG . 2 - FIG . 7 depict elements and 35 cylinder outer radius 24 is 180 millimeters (mm ). The outer
steps that may be implemented optionally in the method 100 cylinder inner radius 25 is 100 mm . The multilayer tube 20
according to the present disclosure . shown in FIG . 8 and FIG . 9 has an inner cylinder 23 made
In FIG . 2 , box 110 depicts, “ inputting a finite element from aluminum having an elastic modulus of about 72 GPa
model of an initial structural design via a user interface . ” For and a Poisson's ratio of about 0.30 . The inner cylinder outer
example , a Computer Aided Design ( CAD ) model may be 40 radius 26 is 100 mm . The inner cylinder inner radius 27 is
created at a design workstation ( the user interface ) or 60 mm . When the finite element model is input ( i.e. step 110 )
imported from a computer memory at the command of an for the initial structural design of the multilayer tube 20 , the
operator manipulating controls of the user interface. A finite initial penetration of the inner cylinder 23 on the outer
element mesh that divides the CAD model into elements is cylinder 22 is 0.1 mm . For example, the finite element model
generated at the design workstation . In some examples of the 45 of the initial structural design may represent a press - fit joint
present disclosure, the finite element mesh is generated or a shrink fit joint between the inner cylinder 23 and the
automatically. outer cylinder 22 with an overlap of 0.1 mm . Because of the
At FIG . 2 , box 120 , is “ defining design and non -design elasticity of the inner cylinder 23 and the outer cylinder 22 ,
space on the initial structural design .” In a first example used the initial penetration of 0.1 mm is shared partly by the
to illustrate the method 100 , the initial structural design may 50 expansion of the outer cylinder 22 and partly by the com
be a multilayer tube 20 as shown in FIG . 8. In examples of pression of the inner cylinder 23. In the present disclosure ,
the present disclosure, the multilayer tube 20 may be a short computer simulation is , in part, used to determine what
or a long tube. A short tube has a length to diameter aspect portion the inner cylinder 23 and the outer cylinder 22 each
ratio of under about 10. A long tube has a length to diameter contribute to absorbing the initial penetration. A press- fit
aspect ration of greater than about 10. Because of the 55 joint and a shrink fit joint are examples of mechanical
symmetry of the multilayer tube 20 , the design space can be interference -based joints included at block 113 of FIG . 3 .
reduced to a single quadrant of the cross - section , as shown FIG . 10A and FIG . 10B depict a finite element mesh
in FIG . 9. Reducing the design space reduces the time to generated on the cross - section depicted in FIG . 9. Friction is
generate a finite element mesh , and reduces computation modeled on FIG . 11 at the contact edges 28 , 28 ' between the
time in a computer simulator. In FIG . 2 , at box 130 , is 60 inner cylinder 23 and the outer cylinder 22. FIG . 12 depicts
" setting up topology optimization parameters. ” At box 140 definition of symmetric boundary conditions on the finite
is “ iteratively optimizing topology variations from the initial element model. A first symmetry region boundary is
structural design by varying the topology optimization depicted at reference numeral 32 and a second symmetry
parameters in a computer simulator running a computer region boundary is depicted at reference number 33 .
simulation until topology optimization criteria are satisfied 65 To simulate a press - fit joint, elements with appropriate
to generate a topology optimized design . ” At box 150 is properties are defined between the mating surfaces in the
“ storing the topology optimized design in a first three finite element model . The following three types of elements
US 10,865,867 B2
7 8
may be used in combination to simulate a press - fit joint: ( 1 ) Similarly Equation (4 ) is used to calculate the radial stress
Contact elements (2 ) Gap elements (3 ) Beam elements . 0, at the inner cylinder contact surface 34. Equation ( 5 ) is
Other elements that further define geometries and constitu- used to calculate the circumferential stress og at the inner
tive capability or interactions can also be used . cylinder contact surface 34 .
In a simulation including the contact elements, a set of 5
contact elements are created between the contacting surfaces
with an appropriate interference value . Gap elements con
nect elements that come into contact during a static analysis
or =
Para
ri – r?
= -ps j (4 )
and a force exerted by the gap element is a function of its 10 -Pcm + r (5 )

length or nodal distance . =
(r? -
The simulation may include linear or non - linear analysis .
A force -displacement function for the elements in the finite
element model depends on whether the simulation uses The circumferential strain Ep at the outer cylinder outer
linear or non - linear analysis . Contact elements find the 15 wall 36 is :
location where contact occurs . However, in simulations with
gap elements , contact is defined to occur at the gap elements.
In the first example ( FIG . 8 ) , an Augmented Lagrangian u 1
(00-00r)
(6 )
algorithm was used to simulate the press - fit with contact E
E
elements . The coefficient of friction , interference value and 20
geometrical dimension of the inner cylinder 23 and the outer
cylinder 22 were some of the parameters for simulating the Expression for outer cylinder radial displacement can be
design of the press - fit multilayer tube 20. PLANE 183 obtained by substituting equations 2 & 3 in equation 6 :
elements were used in the simulation of the first example.
Frictional contacts with coefficient of friction of 0.3 were 25
defined between the contact edges . The element types were Pere Trž + r? +0 (7 )
Ur2 =
CONTA172 and TARGE169. The Augmented Lagrangian Err
contact algorithm simulated the 0.1 mm interference with
frictional contact.
The results of the example simulation were presented 30
Similarly substituting equations 4 & 5 in equation 6 to get
using color contour plots . However, since color contour the radial displacement at the contact surface of inner
plots would not reproduce well in black and white figures cylinder:
herein , some of the results of the example simulation are
presented as follows: Radial deformation at the outer cyl
inder 22 was 0.03 mm (elongation) and at the inner cylinder - Parc Tr ? + (8)
35
23 , the radial deformation was 0.07 mm ( compression ). The E [r - r
summation of total radial deformation was 0.1 mm which is Total interference 8 = 01 - 82 (9 )
equal to the input interference entered in the finite element
model through the contact offset parameter.
The multilayer tube 20 was chosen as for the first example 40 Where ,
to illustrate the method 100 of thepresent disclosure because
classical analytical methods may be used to verify the results 8 , is radial deformation experienced by inner cylinder 23
of the disclosed Finite Element Analysis based simulation 8 , is radial deformation experienced by outer cylinder 22
for the multilayer tube 20. The classical analytical method is Substituting equation 7 & 8 in equation 9
provided below for comparison . 45
FIG . 13 illustrates the pressure 95 at the outer cylinder
contact surface 35 and FIG . 14 illustrates the pressure 95 at Parc Trž + putri ( 10 )
the inner cylinder contact surface 34 . = +
E rž – r2 m2
Equation ( 2 ) is used to calculate the radial stress o, at the
outer cylinder contact surface 35. Equation ( 3 ) is used to 50
calculate the circumferential stress og at the outer cylinder Rearranging equation 10 for contact pressure
contact surface .
?? ( 11 )
Para ( 2) Pc =
or = = -Pc 55 [ rž + r? + r ?
rž - ic
-r r ?
para +
=
rž – r ? Circumferential stress on inner cylinder inner wall 37 is :
60
Where,
r? is inner cylinder inner radius -2pr2 ( 12)
rci is inner cylinder outer radius Cor= rl = per
r2 is outer cylinder outer radius
rc2 is outer cylinder inner radius 65
Pe is the contact pressure Circumferential stress on the outer cylinder inner wall 38
re is the radius at contact surface is:
US 10,865,867 B2
9 10
characteristic traction - separation law to a special embedded
( 13 ) set of finite elements in the finite element analysis based
co /r= rc = Pc
simulation . FIG . 15 depicts an arrangement of cohesive zone
elements 47. Cohesive zone elements 47 act as potential
5 fracture planes having an opening stress profile, i.e. the
Equivalent von- Mises stress expression : stress as a function of the crack face separation, governed by
one or more traction - separation laws.
( 14 ) The cohesive zone method applies a combination of
Oxx + Oyy + ozz - Oxx * Oyy - Oyy 10
fracture theories (Griffith energy based approach (Linear
VM =
Ozz - Ozz * Oxx + 3 (T2y + Tyz + Tz ) Elastic Fracture Mechanics) and Inglis strength based
approach ) based on strength and energy via the character
istic traction -separation laws . Yang et al . (Mixed -mode
Simplifying equation 14 for 2D case (029 Tyz = Tzx = 0 ) fracture analyses of plastically -deforming adhesive joints Q
D Yang, MD Thouless, International Journal of Fracture 110
Our Von Py + 3Txy? ( 15 ) 15 (2 ) , 175-187 ) developed user - defined elements, which pro
Substitute equations 2 , 3 , 4 , 5 , 12 & 13 in equation 14 to vide a means of modeling 2 - D mixed mode fracture by
calculate the von - Mises stress at the inner wall , contact defining a traction -separation law for each fracture mode . As
surface and outer wall of the inner cylinder 23 and the outer the geometry is loaded, the crack plane faces separate and
cylinder 22 . each cohesive element applies traction to the interface
For thermal shrink fit analysis a similar approach can be 20 planes according to its traction -separation laws . Equation 17
used . The contraction ( d , ) of aluminum inner cylinder 23 presents the empirical failure criterion for cohesive ele
and expansion of steel outer cylinder 22 ( 82 ) is calculated by ments:
using equation 16 through thermal loads ( temperature dif
ference ). So the same press - fit finite element analysis based 25
methodology is used for shrink fit analysis . G, + 9 =1
( 17 )
Ti Tu
d = aL (AT) ( 16 )
Where,
d = Total deformation . & Strain energy release rate
a = Coefficient of thermal expansion. 30 1 - Toughness
L = Nominal length of the part being heated . Subscripts: I – Mode I; II — Mode II
AT = Temperature difference . FIG . 16 depicts examples of steps in the cohesive zone
Table 1 shows that the stresses calculated using the method as disclosed herein . In FIG . 16 , the steps are :
classical analytical method yield nearly identical values to Experimental test 40 ; Generating traction separation law 41 ;
the stresses produced using the finite element analysis based 35 Analysis
Defining (cohesive zone elements 42 ; and Finite Element
FEA) model with Cohesive Zone Model ( CZM )
simulation.
43. In FIG . 4 , at box 116 , is “ wherein the cohesive zone
TABLE 1 method includes: determining traction -separation laws for a
mode I crack separation and a mode II crack separation of
Stress - Classical 40 the first material and the second material bonded by the
Analytical Method Stress - FEA adhesive ; defining the cohesive zone elements in a finite
Location ( MPa) ( MPa) element model , wherein defining the cohesive zone elements
Inner Cylinder Inner Wall 37 174.1 174.0 includes generating a mesh for the cohesive zone elements
Inner Cylinder Outer Wall 39
Outer Cylinder Inner Wall 38
102.6
141.8
102.5
141.8
and applying the traction -separation laws as elemental prop
Outer Cylinder Outer Wall 36 49.7 49.7 45 erties of the cohesive zone elements; and executing the finite
element method algorithm including the cohesive zone
module .” In FIG . 4 , the flowchart connector C indicates a
At FIG . 3 , box 114 , is " wherein : the first material is connection between box 116 and box 117 shown in FIG . 5 .
bonded to the second material by an adhesive disposed The traction - separation laws are generated based on cou
between the first material and the second material, thereby 50 pon level tests with respect to crack separation modes ( e.g. ,
forming the joint; and the joint is an adhesively bonded mode I and mode II ) . The traction - separation laws are used
joint . ” In FIG . 3 , the flowchart connector B indicates the as an elemental property for cohesive zone elements to
connection between box 114 and box 115 shown in FIG . 4 . predict the behavior of the various geometries. In FIG . 5 , the
In FIG . 3 , a flowchart connector D indicates a connection flowchart connector C indicates the connection between box
between box 112 and box 142 shown in FIG . 6. In FIG . 3 , 55 117 and box 116 shown in FIG . 4. In box 117 , FIG . 5 depicts
a flowchart connector E indicates a connection between box
112 and box 143 shown in FIG . 7 .
“ wherein the determining traction -separation laws includes
empirically determining the traction -separation laws from a
In FIG . 4 , the flowchart connector B indicates the con- double cantilever beam test to determine the traction -sepa
nection between box 114 shown in FIG . 3 and box 115. In ration law for the mode I crack separation and a lap shear test
box 115 , FIG . 4 depicts " wherein : a cohesive zone method 60 to determine the traction -separation law for the mode II
is applied to model cohesive zone elements of the adhesively crack separation . ” FIG . 17 illustrates a test setup for a
bonded joint; and a finite element method algorithm includ- Lap - Shear Test ( Mode II ) . An adhesive lap joint specimen
ing a cohesive zone module calculates stresses and strains 98 is placed in tensile shear as indicated by the Mode II load
under internal and external loads ." arrows 79. FIG . 18 illustrates a test setup for a double
As disclosed herein , examples of the cohesive zone 65 cantilever beam test ( Mode I ) . A double cantilever beam
method are numerical methods for modeling fracture . specimen 87 has a pre - crack 89 and is loaded as shown at
Examples of the cohesive zone method include assigning a Mode I load arrows 91. At box 118 , FIG . 5 depicts “ wherein :
US 10,865,867 B2
11 12
the double cantilever beam test method is defined by ASTM OptiStruct v. 12.0 were used for the Finite Element Model
D5528 ; and the lap shear test method is defined by ASTM setup , optimization formulation and performing optimiza
D5868 .” Note that the American Society for Testing and tion runs . HyperView v. 12.0 was used to post process the
Materials (ASTM) changed its name to “ ASTM Interna- results.
tional” in 2001 . 5 The second example, referred to above, is an example that
In FIG . 6 , the flowchart connector D indicates the con- applies the method of the present disclosure in the formu
nection between box 112 shown in FIG . 3 and box 142. In lation stated as follows:
box 142 , FIG . 6 depicts “ wherein varying the topology Objective: Maximize stiffness of the structure (minimize
optimization parameters includes: determining an elemental compliance ), where the structure is the multilayer tube 20 ' .
density for each element of the finite element model ; deter- 10 Constraints: Stress value , volume fraction and manufac
mining a minimum density threshold based on a weight turing ( extrusion method )
savings percentage target and a mapping of the elemental Design variables : Element density
density on the finite element model ; setting the elemental In the second example, optimization runs were performed
density to zero for each of the elements of the finite element with objective function of minimizing the weight within the
model having an elemental density less than the minimum 15 following criteria: ( 1 ) stiffness, (2) design space, ( 3) stress/
density threshold ; and assigning the elemental density to 1 deformation, and ( 4 ) manufacturing constraints. Since the
for each of the elements of the finite element model having initial results of topology optimization may not have been
an elemental density greater than or equal to the minimum realistic , multiple iterations were applied for the topology
density threshold ; and varying the topology optimization optimization to convergence with practical results . Next,
parameters in the elements of the finite element model 20 size
having the elemental density assigned to 1. "
and shape optimization was used to fine tune the results
from topology optimization with the objective function to
In FIG . 7 , the flowchart connector E indicates the con- meet the overall performance objectives.
nection between box 112 shown in FIG . 3 and box 143. In A Finite Element Analysis computer simulation was run
box 143 , FIG . 7 depicts “ wherein the evaluating geometry on the design space 29 to determine which of the elements
optimization criteria includes : defining relationships 25 ( finite elements ) were load bearing elements. The computer
between an overall cost and the geometric optimization simulator produced a graphical display, depicting elements
parameters; and calculating the overall cost for each geom- with an elemental density of 1 in a red color to indicate that
etry design iteration .” At box 144 , is “ wherein the overall such elements were load -bearing elements . As used herein ,
cost includes a material cost and a manufacturing cost . ” At elemental density means a number of finite elements in a
box 146 , is “ wherein the geometric optimization parameters 30 particular space . When a finite element mesh is generated ,
include : a quantity of a variable design feature ; a size of the areas with higher loading are given smaller elements to
variable design feature; or a shape of the variable design improve the model without adding calculation burden for
feature ." At box FIG . 7 depicts “ wherein the variable areas that are lightly loaded . The graphical display depicted
design feature includes a hole, a fillet, or a chamfer." elements with elemental density of O as blue elements to
As disclosed herein , topology optimization would have 35 indicate that such blue elements were non - load bearing
utility at the concept level of the design cycle to arrive at a elements that could be neglected . Thus , an understanding of
conceptual design which meets the overall performance and the structurally important areas was gained . Since the red
manufacturability. Identifying the design and non - design and blue color would not reproduce in black and white , a
space is one of the first steps of the topology optimization . depiction of the graphical display has been omitted .
FIG . 19 is a flow chart representing a method 100 ' that 40 Based on a weight savings constraint and the element
combines topology optimization with shape and size opti- density plots , an elemental density threshold was set . Ele
mization as disclosed herein . The work flow of topology ments with an elemental density value below the elemental
optimization with shape and size optimization is divided in density threshold were neglected ; hence a contribution of the
three phases. Phase 1 includes the design and non -design neglected elements to the overall stiffness of the structure
space segregation shown at box 51 , and optimization prob- 45 was also nullified . FIG . 21 depicts a cross - sectional view of
lem formulation through evaluation of results shown at a finite element model depicting the neglected elements 44
reference numeral 52. Phase 2 includes extracting the geom as white . Darker colors in FIG . 21 indicate load bearing
etry from the Phase 1 optimization results at box 53 and elements 45. To counterbalance the removal of the neglected
interpreting and redesigning to obtain a realistic geometry at elements 44 from the analysis, all elements with densities
box 54. Phase 3 includes iteratively performing Finite Ele- 50 greater than the threshold were assigned a new standardized
ment simulation to optimize and validate the redesigned density value 1 , which implies that the stiffness of the
geometry. remaining elements was equally increased .
FIG . 20 is a cross -sectional view of a multilayer tube 20 ' Next , the geometry of the second example was refined
presented herein to illustrate a second example of the considering manufacturing constraints . The manufacturing
method of the present disclosure. The multilayer tube 20 ' 55 constraints considered were manufacturing limits on mini
includes three tubular elements joined together using any mum thickness and machining cost . The neglected elements
suitable joining technique including a mechanical interfer- 44 in the topology optimization suggested a number of holes
ence based joining technique or an adhesive bonding tech- 62 , voids , or slots as shown in FIG . 21. The number of holes
nique. FIG . 20 illustrates the defining of the design and the 62 ( i.e. , 20 holes in FIG . 21 ) may have been manufacturable ;
non -design space . In the example depicted in FIG . 20 , the 60 however there was an opportunity for cost improvement
design space 29 is the middle layer, between the outer layer since the metal extrusion process required a mandrel for
31 and the inner layer 30. The outer layer 31 and the inner each hole 62 shown to get the desired shape . There was an
layer 30 are “ non - design space ” as indicated in FIG . 20. The opportunity to optimize weight and cost by reducing the
design space 29 incorporates a lighter material from the first number of holes 62 and the web thickness within the stress
example of joining techniques described herein above . The 65 constraint.
design space 29 was iteratively changed in a computer The methodology of parametric design optimization or
simulator to find the optimized design . HyperMesh and size and shape optimization was used to further fine tune the
US 10,865,867 B2
13 14
geometry . FIG . 22 is a flow chart depicting a work flow of flange 12 and to the steel hub 11 so the gear 10 rotates as a
a size and shape optimization process 100 " . This approach solid body. In other words the steel toothed annular flange
is similar to the parametric method where the predefined 12 , the web 13 , and the steel hub 11 rotate together,
design variables include a hole , a fillet, or a chamfer. substantially without relative motion . “ Substantially without
Therefore design variables can be determined through a 5 relative motion ” in the previous sentence means any relative
relationship between geometric dimensions and the design motion would not be visible to the naked eye during opera
variables. During each iteration, the design variables were tion of the gear 10. Because the materials of the steel toothed
modified and the geometric model was modified accord- annular flange 12 , the web 13 , and the steel hub 11 have
ingly . The mesh was automatically updated in the Finite different elastic properties and thermal responses , the parts
Element Model . 10 (i.e. the steel toothed annular flange 12 , the web 13 , and the
After multiple iterations, the objective function was met steel hub 11 ) may experience a small amount of relative
and all constraints satisfied . FIG . 23 is a grayscale contour motion that would only be detectable with sensitive instru
plot of finite element model depicting the results of the mentation . The gear 10 is to operatively transmit a torque of
second example after the geometry was refined considering at least 500 Newton Meters ( N • m ) for at least 6 million
manufacturing constraints and applying the size and shape 15 revolutions of the gear 10. An overall mass of the gear 10 is
optimization process 100 " . The cross - section shown in FIG . less than two - thirds of an overall mass of a same - sized all
23 is lighter and less costly to manufacture than the cross- steel gear having a solid steel web with a solid steel web
section shown in FIG . 21. In FIG . 21 , there are 20 holes 62 . thickness 17 at least one - third of a face width 46 ( see FIG .
In FIG . 23 , there are 19 holes 62 ' . Manufacturing fewer 24B ) of the steel toothed annular flange 12 .
holes 62 , 62 ' translates to lower tooling costs for mandrels. 20 In examples of the present disclosure, the web 13 may be
The holes 62 ' in FIG . 23 are larger than the holes 62 in FIG . bonded to the steel toothed annular flange 12 with a first
21 , therefore , a weight savings was realized in the design layer 48 of an adhesive 49. The web 13 may be bonded to
depicted in FIG . 23 compared to the design depicted in FIG . the steel hub 11 with a second layer 58 of the adhesive 49 .
21. The lighter, less costly design depicted in FIG . 23 met In examples, the first layer 48 of the adhesive 49 and the
the performance objectives ( i.e. stiffness , design space , 25 second layer 58 of the adhesive 49 may be about 0.25 mm
stress /deformation ) within the manufacturing constraints. thick .
In an example of the present disclosure depicted in FIG . In other examples, the web 13 may be retained in the steel
24A , a gear 10 for transmitting torque includes a steel toothed annular flange 12 by a first mechanical interference
toothed annular flange 12 having gear teeth 14 defined on a joint 55 ( see , e.g. FIG . 24A) between the steel toothed
periphery 15 of the steel toothed annular flange 12. The 30 annular flange 12 and the web 13. The steel hub 11 may be
whole steel toothed annular flange 12 is steel . The gear teeth retained in the web 13 by a second mechanical interference
14 are steel , and the flange that supports the gear teeth 14 is joint 56 ( see , e.g. FIG . 24A) between the web 13 and the
steel . The gear teeth 14 on the steel toothed annular flange steel hub 11. As stated above , in examples of the present
12 may be any type of gear tooth 14 that is capable of disclosure, mechanical interference joints 55 , 56 can include
meeting the loading requirements of the gear 10. For 35 a thermal shrink - fit joint and / or a mechanical press - fit joint.
example, the gear 10 may have spur gear teeth , helical gear In the example depicted in FIG . 27 , a plurality of first lugs
teeth , or double helical gear teeth . 61 is defined at first spaced intervals 57 on an interior
A steel hub 11 is coaxially aligned with the steel toothed surface 92 of the steel toothed annular flange 12. A plurality
annular flange 12. A web 13 is formed from a web material of first grooves 63 is defined in an outer web circumferential
16 having a density less than or equal to 3.0 grams per cubic 40 surface 64. The plurality of first grooves 63 is complemen
centimeter ( g / cm ). For example the web material 16 may be tary to the plurality of first lugs 61. A total quantity of the
aluminum , an aluminum alloy, a fiber reinforced polymer first grooves 63 is at least equal to a total quantity of the first
composite , or combinations thereof. The web 13 may have lugs 61. In the example depicted in FIG . 27 , the total
a uniform web thickness 17 except in locations on the web quantity of the first grooves 63 is equal to the total quantity
13 where lightening apertures 18 are defined in the web 13. 45 of the first lugs 61. In the example depicted in FIG . 27 , the
The inventors of the present disclosure have fortuitously total quantity of the first grooves 63 is 12. A plurality of
and unexpectedly discovered that the optimum total quantity second lugs 66 is defined at second spaced intervals 59 on
of the lightening apertures 18 may depend on the web an exterior surface 68 of the steel hub 11. A plurality of
material 16. For example, the optimum total quantity of the second grooves 67 is defined in an inner web circumferential
lightening apertures 18 is seven when the web material is 50 surface 69. The plurality of the second grooves 67 is
aluminum or an aluminum alloy ; and the optimum total complementary to the plurality of the second lugs 66. A total
quantity of the lightening apertures 18 is thirteen when the quantity of the second grooves 67 is at least equal to a total
web material is a fiber reinforced polymer composite . In this quantity of the second lugs 66. In the example depicted in
case , the optimization included weight reduction of the gear. FIG . 27 , the total quantity of the second grooves 67 is equal
In examples that have the fiber reinforced polymer com- 55 to the total quantity of the second lugs 66. In the example
posite web material, the web material 16 may be reinforced depicted in FIG . 27 , the total quantity of the second grooves
with glass fiber, carbon fiber, or combinations thereof. As 67 is 12 .
depicted in FIG . 28 , the web material 16 may have a A first ratio of a first lug arc length 71 to a first inter -lug
plurality of layers 21 of fiberglass reinforcement. Each layer space arc length 72 may be equal to a first strength ratio of
21 can include fibers aligned parallel to a layer fiber align- 60 a shear strength of the web material 16 to a shear strength of
ment axis 19 of each layer 21. The layer fiber alignment axis the steel in the steel toothed annular flange 12. A second ratio
19 of each layer 21 can be skewed with an adjacent layer of a second lug arc length 73 to a second inter -lug space arc
fiber alignment axis of an adjacent layer. In this way, the length 74 may be equal to a second strength ratio of the shear
physical properties of the web 13 are isotropic from a strength of the web material 16 to a shear strength of the
macroscopic perspective . 65 steel in the steel hub 11. The first lug arc length 71 and the
In an example of the present disclosure depicted in FIG . first inter-lug space arc length 72 are determined at a first
27 , the web 13 is fixedly attached to the steel toothed annular root circle 75 of the plurality of the first lugs 61. The second
US 10,865,867 B2
15 16
lug arc length 73 and the second inter - lug space arc length toothed ring gear 81 ' and the steel hub 83 ' had corresponding
74 are determined at a second root circle 76 of the plurality oval shapes to complement the aluminum core 82 ' . Since the
of the second lugs 66 . toothed surface of the toothed ring gear 81 ' is round, the
ovality caused a thinner area 84 of the toothed ring gear 81 ' .
Experimental Test Results 5 The toothed ring gear 81 ' cracked ( at the thinner area 84 )
early in torque cycle testing. The torque cycle testing
Gears are subjected to an array of design verification tests included 10 million cycles on a torque test fixture at 4500
to assure a new gear design meets or exceeds design ft - lbs ( foot pounds ). The crack occurred at the thinnest area
requirements. Actual hardware tests , not computer simula- 10
of the toothed ring gear 81 ' . No other testing was performed
tions , were used to compare gears 10 that were designed on the Conventional Example C.
using the structural optimization method 50 to gears that
weredesignedusing more conventionalexisting engineering Example D
methods . The tests results summarized below show that all
of the attempts to design lightweight, high -torque gears with 15
A representative sample of example D ( according to an
conventional techniques resulted in gears that could not example of the present disclosure ) is shown in FIG . 27. The
meet the design validation test requirements. As disclosed gear 10 has a steel toothed annular flange 12 having gear
herein , only the gears designed by the method of the present teeth 14 defined on a periphery 15 of the steel toothed
disclosure were able to meet all of the design validation test annular flange 12. The gear teeth 14 on the steel toothed
targets including thermal range, impact loading, and fatigue
durability.In testing on test stands the gear designs thatused 20 annular flange1112isarecoaxially
A steel hub spur gearaligned
teeth with
withantheinvolute profile.
steel toothed
classical Euler theory techniques of design such as the annular flange 12. A web 13 is formed from a fiberglass
“ Shrink Fit ” -based design shown in FIG . 25 and FIG . 26 all reinforced polymer composite 77 that has a uniform web
failed to meet at least one of the design validation test thickness 17 ( see , e.g. , FIG . 24B ) of about 27 mm . The web
requirements. In sharp contrast, all samples of all gears 10
designed using the method of the present disclosure passed 25 1312 isandadhesively bonded to the steel toothed annular flange
to the steel hub 11 with epoxy. A centering fixture
10 % of the design Validation testing while achieving a based on concentric arbor -expanders was used to control
lightweighting capability of one -third reduction of mass runout during assembly. Runout was less than 0.005 mm
compared to the current all - steel gear designs . with no need for final grinding of the gear teeth 14. The steel
Conventional Example A 30 toothed annular flange 12 has 12 equally spaced first lugs 61 .
The steel hub 11 has 12 equally spaced second lugs 66. The
A representative sample of conventional example A is first lugs 61 are each centered at angles 88 that bisect
shown in FIG . 25. The gear assembly has a toothed ring gear circular sectors 86 defined by each adjacent pair of second
81 , an aluminum core 82 , and a steel hub 83 assembled using lugs 66 and the center axis 78 of the gear 10 .
a light shrink fit to form a mechanical interference joint. A 35 Example D was designed using the method 100 of the
light shrink fit is a thermal shrink fit that establishes a light present disclosure including the cohesive zone method .
drive fit according to ANSI B 4.1 . Conventional Example A Example D met all of the design verification test require
relied on residual stresses at the shrink fit joint to hold the ments. The Example D test specimens passed the thermal
parts of the assembly together. Conventional Example A shake test that conventional example A and conventional
experienced a loosening of the first mechanical interference 40 example B could not pass . The Example D test specimens
joint 55 during a thermal shake test . The temperature range passed the torque cycle tests that conventional example C
for the thermal shake test was from -50 degrees Fahrenheit could not pass . Further, Example D passed a 90,000 cycle
( ° F. ) to 350 ° F. with a maximum acceleration in the thermal impact test in an Eaton Fuller transmission . During static
chamber being 50 g ( g is the standard value of gravitational torque load tests , Example D reached higher static torque
acceleration at sea level on Earth ) . 45 loadings than the production steel gear that Example D was
designed to replace. When an Eaton Fuller FRO - 16210C
Conventional Example B transmission was tested for Noise Vibration and Harshness
(NVH ) with and without one Example D gear installed as a
A representative sample of conventional example Bis mainshaft gear, the drive -by sound intensity was reduced
also shown in FIG . 25. The gear assembly has a toothed ring 50 overall by 3 dB , and for many loud frequencies by 5 dB .
gear 81 , an aluminum core 82 , and a steel hub 83 assembled It is to be understood that the terms " connect /connected /
using a medium shrink fit to form the mechanical interfer- connection ” and / or the like are broadly defined herein to
ence joints. A medium shrink fit is a thermal shrink fit that encompass a variety of divergent connected arrangements
establishes a medium drive fit according to ANSI B 4.1 . and assembly techniques. These arrangements and tech
Conventional Example B experienced a loosening of the first 55 niques include, but are not limited to ( 1) the direct commu
nication between one component and another component
mechanical interference joint 55 during the thermal shake
test . with no intervening components therebetween ; and (2 ) the
communication of one component and another component
Conventional Example C with one or more components therebetween , provided that
60 the one component being " connected to ” the other compo
A representative sample of conventional example C is nent is somehow in operative communication with the other
shown in FIG . 26. The gear assembly has a toothed ring gear component (notwithstanding the presence of one or more
81 ' , an aluminum core 82 ' , and a steel hub 83 ' assembled additional components therebetween ).
using a heavy shrink fit to form the mechanical interference Further, it is to be understood that when “ about” is utilized
joints. A heavy shrink fit is a thermal shrink fit that estab- 65 to describe a value , this is meant to encompass minor
lishes a heavy drive fit according to ANSI B 4.1 . Conven- variations ( +/- 10 % from the stated value (e.g. , about 0.025
tional Example C had an oval aluminum core 82 ' . The steel inch is 0.023 inch to 0.027 inch )).
US 10,865,867 B2
17 18
Reference throughout the specification to “ one example ” , a plurality of second grooves defined in an inner web
“ another example ”, “ an example ” , and so forth , means that circumferential surface wherein the plurality of second
a particular element (e.g. , feature, structure , and / or charac- grooves is complementary to the plurality of the second
teristic ) described in connection with the example is lugs , and wherein a total quantity of second grooves is
included in at least one example described herein , and may 5 at least equal to a total quantity of the second lugs .
or may not be present in other examples. In addition , it is to 5. The gear as defined in claim 4 wherein :
be understood that the described elements for any example a first ratio of a first lug arc length to a first inter - lug space
may be combined in any suitable manner in the various arc length is equal to a first strength ratio of a shear
examples unless the context clearly dictates otherwise . strength of the web material to a shear strength of the
In describing and claiming the examples disclosed herein , 10 steel in the steel toothed annular flange;
the singular forms “ a ” , “ an ”, and “ the ” include plural a second ratio of a second lug arc length to a second
referents unless the context clearly dictates otherwise . inter- lug space arc length is equal to a second strength
While several examples have been described in detail, it ratio of the shear strength of the web material to a shear
is to be understood that the disclosed examples may be strength of the steel in the steel hub ;
modified . Therefore, the foregoing description is to be 15 the first lug arc length and the first inter - lug space arc
considered non-limiting . length are determined at a first root circle of the
plurality of the first lugs ; and
What is claimed is : the second lug arc length and the second inter- lug space
1. A gear for transmitting torque, comprising: arc length are determined at a second root circle of the
a steel toothed annular flange having gear teeth defined on 20 plurality of the second lugs.
a periphery thereof; 6. The gear as defined in claim 1 wherein the web has a
a steel hub coaxially aligned with the steel toothed uniform web thickness .
annular flange; and 7. The gear as defined in claim 1 wherein a plurality of
a web formed from a web material having a density less lightening apertures are defined in the web, and the web has
than or equal to 3.0 grams per cubic centimeter ( g /cmº), 25 a uniform web thickness except in locations on the web
the web fixedly attached to the steel toothed annular where each of the lightening apertures is defined in the web .
flange and to the steel hub for rotation therewith , 8. The gear as defined in claim 7 wherein
wherein the gear is to operatively transmit a torque of the total quantity of the lightening apertures is thirteen .
at least 500 Newton Meters (Nm ) for at least 6 million 9. A computer implemented method for designing a gear
revolutions of the gear; 30 for transmitting torque, the method comprising:
wherein an overall mass of the gear is less than two - thirds inputting a finite element model of an initial structural
of an overall mass of a same - sized all steel gear having design via a user interface;
a solid steel web with a solid steel web thickness at defining design and non- design space on the initial struc
least one - third of a face width of the steel toothed tural design;
annular flange; wherein : 35 setting up topology optimization parameters ;
the web material is a fiber reinforced polymer composite ; iteratively optimizing topology variations from the initial
the web material is reinforced with glass fiber, carbon structural design by varying the topology optimization
fiber , or combinations thereof; parameters in a computer simulator running a computer
the web material includes a plurality of layers of fiberglass 40 simulation until topology optimization criteria are sat
reinforcement; isfied to generate a topology optimized design ;
each layer includes fibers aligned parallel to a layer fiber storing the topology optimized design in a first three
alignment axis of each layer; and dimensional modeling format ;
the layer fiber alignment axis of each layer is skewed with iteratively optimizing geometry variations from the topol
an adjacent layer fiber alignment axis of an adjacent ogy optimized design by varying geometric optimiza
layer. 45 tion parameters of each geometry design iteration in the
2. The gear as defined in claim 1 wherein : computer simulator running the computer simulation
the web is bonded to the steel toothed annular flange with and evaluating geometry optimization criteria until
a first layer of an adhesive; and geometry optimization targets are satisfied to generate
the web is bonded to the steel hub with a second layer of a geometry optimized design ;
the adhesive . 50 storing the geometry optimized design in a second three
3. The gear as defined in claim 1 wherein : dimensional modeling format; and
the web is retained in the steel toothed annular flange by generating a hardware prototype according to the geom
a first mechanical interference joint between the steel etry optimized design , wherein the gear for transmitting
toothed annular flange and the web ; and torque includes:
the steel hub is retained in the web by a second mechani- 55 a steel toothed annular flange having gear teeth defined
cal interference joint between the web and the steel on a periphery thereof;
hub . a steel hub coaxially aligned with the steel toothed
4. The gear as defined in claim 1 , further comprising: annular flange; and
a plurality of first lugs defined at spaced intervals on an a web formed from a web material having a density less
interior surface of the steel toothed annular flange; 60 than or equal to 3.0 grams per cubic centimeter
a plurality of first grooves defined in an outer web ( g /cm3 ), the web fixedly attached to the steel toothed
circumferential surface wherein the plurality of the first annular flange and to the steel hub for rotation
grooves is complementary to the plurality of the first therewith , wherein the gear is to operatively transmit
lugs , and wherein a total quantity of the first grooves is a torque of at least 500 Newton Meters (Nm ) for at
at least equal to a total quantity of the first lugs ; 65 least 6 million revolutions of the gear ;
a plurality of second lugs defined at spaced intervals on an wherein an overall mass of the gear is less than two
exterior surface of the steel hub ; and thirds of an overall mass of a same - sized all steel
US 10,865,867 B2
19 20
gear having a solid steel web with a solid steel web setting the elemental density to zero for each of the
thickness at least one - third of a face width of the elements of the finite element model having an elemen
steel toothed annular flange; wherein : tal density less than the minimum density threshold ;
the web material is a fiber reinforced polymer compos and
ite ; 5 assigning the elemental density to 1 for each of the
the web material is reinforced with glass fiber, carbon elements of the finite element model having an elemen
fiber, or combinations thereof; tal density greater than or equal to the minimum density
the web material includes a plurality of layers of threshold ; and
fiberglass reinforcement; varying the topology optimization parameters in the ele
each layer includes fibers aligned parallel to a layer 10 ments of the finite element model having the elemental
fiber alignment axis of each layer; and density assigned to 1 .
the layer fiber alignment axis of each layer is skewed 17. The method as defined in claim 10 wherein :
with an adjacent layer fiber alignment axis of an the evaluating geometry optimization criteria includes:
adjacent layer. defining relationships between an overall cost and the
10. The method as defined in claim 9 wherein : 15 geometric optimization parameters, and
the initial structural design includes a first material and a calculating the overall cost for each geometry design
second material; iteration;
the first material and the second material are dissimilar ; the overall cost includes a material cost and a manufac
and turing cost ;
the first material is joined to the second material thereby 20 the geometric optimization parameters include :
forming a joint, wherein the first material is steel . a quantity of a variable design feature ;
11. The method as defined in claim 10 wherein : a size of the variable design feature; or
the joint is a mechanical interference -based joint; and a shape of the variable design feature; and
the computer simulation includes : the variable design feature includes a hole, a fillet, or a
an Augmented Lagrangian contact algorithm to define 25 chamfer.
a frictional contact between the first material and the 18. A gear for transmitting torque , comprising:
second material at the interference - based joint; and a steel toothed annular flange having gear teeth defined on
a finite element method algorithm to calculate stresses a periphery thereof;
and strains under internal and external loads . a steel hub coaxially aligned with the steel toothed
12. The method as defined in claim 10 wherein : 30 annular flange;
the first material is bonded to the second material by an a web formed from a web material having a density less
adhesive disposed between the first material and the than or equal to 3.0 grams per cubic centimeter
second material, thereby forming the joint; and (g/cm3 ) , the web fixedly attached to the steel toothed
the joint is an adhesively bonded joint . annular flange and to the steel hub for rotation there
13. The method as defined in claim 12 wherein : 35 with ;
a cohesive zone method is applied to model cohesive zone a plurality of first lugs defined at spaced intervals on an
elements of the adhesively bonded joint; and interior surface of the steel toothed annular flange;
a finite element method algorithm including a cohesive a plurality of first grooves defined in an outer web
zone module calculates stresses and strains under inter circumferential surface wherein the plurality of the first
nal and external loads . 40 grooves is complementary to the plurality of the first
14. The method as defined in claim 13 wherein the lugs , and wherein a total quantity of the first grooves is
cohesive zone method includes: at least equal to a total quantity of the first lugs ;
determining traction - separation laws for a mode I crack a plurality of second lugs defined at spaced intervals on an
separation and a mode II crack separation of the first exterior surface of the steel hub; and
material and the second material bonded by the adhe- 45 a plurality of second grooves defined in an inner web
sive ; circumferential surface wherein the plurality of second
defining the cohesive zone elements in a finite element grooves is complementary to the plurality of the second
model, wherein defining the cohesive zone elements lugs , and wherein a total quantity of the second grooves
includes generating a mesh for the cohesive zone is at least equal to a total quantity of the second lugs ;
elements and applying the traction - separation laws as 50 wherein :
elemental properties of the cohesive zone elements; and the gear is to operatively transmit a torque of at least
executing the finite element method algorithm including 500 Newton Meters (N • m) for at least 6 million
the cohesive zone module . revolutions of the gear;
15. The method as defined in claim 14 wherein the an overall mass of the gear is less than two - thirds of an
determining traction - separation laws includes empirically 55 overall mass of a same -sized all steel gear having a
determining the traction -separation laws from a double solid steel web with a solid steel web thickness at
cantilever beam test to determine the traction -separation law least one - third of a face width of the steel toothed
for the mode I crack separation and a lap shear test to annular flange;
determine the traction -separation law for the mode II crack the web material is glass fiber reinforced polymer
separation . 60 composite ;
16. The method as defined in claim 10 wherein varying the web material includes a plurality of layers of
the topology optimization parameters includes : fiberglass reinforcement;
determining an elemental density for each element of the each layer includes fibers aligned parallel to a layer
finite element model ; fiber alignment axis of each layer ;
determining a minimum density threshold based on a 65 the layer fiber alignment axis of each layer is skewed
weight savings percentage target and a mapping of the with an adjacent layer fiber alignment axis of an
elemental density on the finite element model; adjacent layer ;
US 10,865,867 B2
21 22
the web is bonded to the steel toothed annular flange a plurality of second grooves defined in an inner web
with a first layer of an adhesive ; and circumferential surface wherein the plurality of second
the web is bonded to the steel hub with a second layer grooves is complementary to the plurality of the second
of the adhesive; lugs , and wherein a total quantity of second grooves is
a first ratio of a first lug arc length to a first inter - lug 5 at least equal to a total quantity of the second lugs ;
space arc length is equal to a first strength ratio of a wherein :
shear strength of the web material to a shear strength the gear is to operatively transmit a torque of at least
of the steel in the steel toothed annular flange; 500 Newton Meters (N • m) for at least 6 million
a second ratio of a second lug arc length to a second revolutions of the gear;
inter - lug space arc length is equal to a second 10 an overall mass of the gear is less than two - thirds of an
strength ratio of the shear strength of the web mate overall mass of a same- sized all steel gear having a
rial to a shear strength of the steel in the steel hub; solid steel web with a solid steel web thickness at
the first lug arc length and the first inter -lug space arc least one -third of a face width of the steel toothed
length are determined at a first root circle of the annular flange;
plurality of the first lugs ; 15 a first ratio of a first lug arc length to a first inter - lug
the second lug arc length and the second inter - lug space space arc length is equal to a first strength ratio of a
arc length are determined at a second root circle of shear strength of the web material to a shear strength
the plurality of the second lugs ; of the steel in the steel toothed annular flange;
the web has a uniform web thickness except where a second ratio of a second lug arc length to a second
lightening apertures are defined in the web ; and 20 inter-lug space arc length is equal to a second
a total quantity of the lightening apertures is thirteen . strength ratio of the shear strength of the web mate
19. A gear for transmitting torque, comprising: rial to a shear strength of the steel in the steel hub;
a steel toothed annular flange having gear teeth defined on the first lug arc length and the first inter - lug space arc
a periphery thereof; length are determined at a first root circle of the
a steel hub coaxially aligned with the steel toothed 25 plurality of the first lugs ; and
annular flange; and the second lug arc length and the second inter- lug space
a web formed from a web material having a density less arc length are determined at a second root circle of
than or equal to 3.0 grams per cubic centimeter (g/cmº ) , the plurality of the second lugs .
20. The gear as defined in claim 19 wherein the web has
the web fixedly attached to the steel toothed annular 30 a uniform
flange and to the steel hub for rotation therewith , web thickness .
21. The gear as defined in claim 19 wherein a plurality of
a plurality of first lugs defined at spaced intervals on an lightening apertures
interior surface of the steel toothed annular flange; are defined in the web, and the web has
a plurality of first grooves defined in an outer web where a uniform web thickness except in locations on the web
circumferential surface wherein the plurality of the first each of the lightening apertures is defined in the web .
22. The gear as defined in claim 21 wherein the web
grooves is complementary to the plurality of the first 35 material is a fiber reinforced polymer composite and
lugs , and wherein a total quantity of the first grooves is wherein the
at least equal to a total quantity of the first lugs ; total quantity of the lightening apertures is
a plurality of second lugs defined at spaced intervals on an thirteen .
exterior surface of the steel hub ; and

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US010865867B2

( 54 ) LIGHTWEIGHT TORQUE TRANSMISSION ( 58 ) Field of Classification Search

TOPOLOGY TOPOGRAPHY SHAPE SIZE

PHASE OR CONCEPT PHASE FINE TUNE THE DESIGN

TOPOLOGY TOPOGRAPHY SHAPE SIZE

SETTING UP TOPOLOGY OPTIMIZATION PARAMETERS

ITERATIVELY OPTIMIZING TOPOLOGY VARIATIONS FROM THE INITIAL STRUCTURAL DESIGN BY

ITERATIVELY OPTIMIZING GEOMETRY VARIATIONS FROM THE TOPOLOGY OPTIMIZED DESIGN

GENERATING A HARDWARE PROTOTYPE ACCORDING TO THE GEOMETRY OPTIMIZED DESIGN

AN AUGMENTED LAGRANGIAN CONTACT ALGORITHM TO DEFINE THE :

AFINITE ELEMENT METHOD ALGORITHM TO CALCULATE STRESSE 3 :)

AND STRAINS UNDER INTERNAL AND EXTERNAL LOADS 3

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A COHESIVE ZONE METHOD IS APPLIED TO MODEL COHESIVE ZONE ELEMENTS OF THE

1 WHEREIN THE COHESIVE ZONE METHOD INCLUDES :

AND A MANUFACTURING COST

WHEREIN THE GEOMETRIC OPTIMIZATION PARAMETERS INCLUDE :

FIG . 10A FIG . 10B

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PARAMETERS AND SUBMIT RUN 0

SIZE AND PERFORM FE SIMULATION ON 3

NON DESIGN SPACE 20

RECREATED GEOMETRY AFTER

SET UP OPTIMIZATION PARAMETERS

PREPARE MODEL SET UP WITH

SUBMIT RUNS AND CALCULATE

FIG . 24A FIG . 24B

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and a force exerted by the gap element is a function of its 10 -Pcm + r (5 )

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