Robust optimization of hypoid gear contact performance considering tooth form error: Design sensitivity and Pareto front

Optimization of hypoid gear contact performance is challenging due to its nonconvex nature and the handling of non-linear constraints involving complex gear contact behavior. In addition, the contact performance in the existing optimization schemes is highly reliant on the manufacturing quality, for example, the uncertain tooth form errors induced by machining tolerances and blade wear are usually ignored. To tackle these problems, a robust optimization methodology is proposed for hypoid gear contact performance. A finite element/contact mechanics model is established, which considers the stochastic tooth form errors following a Gaussian distribution model. The non-linear constraints are incorporated to avoid edge contact under loaded conditions, and tooth surface interference due to error. This methodology guarantees the feasible solution space and reduces the optimization complexity by the independent identification model. The identification model of the optimal solution is flexible in the parameter selection while keeping tooth depth. This non-deterministic problem is optimized based on the pattern search method. The Pareto front and design sensitivity analysis demonstrate the effectiveness and robustness of the proposed optimization methodology.