Multi-objective design optimization of hypoid geared rotor dynamic system

Noise and vibration in hypoid geared systems remain a critical concern in modern gear design. Existing research studies primarily focus on optimizing the theoretical and static models, which fail to capture the dynamic behaviors directly linked to noise and vibration of hypoid geared systems. To address this gap, a novel optimization model for a hypoid geared rotor dynamic system is developed, aiming to minimize the dynamic response while ensuring gear durability. The optimization scheme integrates a micro-geometry modification framework with a non-uniform discretization-based identification model. First, a three-dimensional static mesh model is established to form system equilibrium and provide initial conditions, and a fourteen-degree-of-freedom (DOF) dynamic model is employed to capture system behavior. Then, a bivariate polynomial surface with five independent, consistently scaled coefficients is used for tooth surface modification and reducing optimization complexity. An identification model is developed to determine the optimal tool and machine settings. Finally, comparative numerical studies and Pareto front analysis are conducted to validate the effectiveness of the model. The trade-off solution is further examined through mesh characteristics and unloaded tooth contact analysis.