Sensitivity analysis of lightweight design concepts in terms of gearbox acoustics

The downsizing of drivetrains often leads to lighter and more flexible structures. The higher elasticity of the system’s components directly affects the existing gear mesh excitation and the transfer paths of the gearbox. For example, higher flexibilities of the housing, shafts and gear blanks cause a larger misalignment in the tooth contacts, which can lead to larger system excitations and to worse acoustic performance. To identify the risks and capabilities of lightweight designs in terms of the gearbox’s acoustic performance, a simulation-based sensitivity analyses and parameter studies shall be carried out. In addition to the investigation of lightweight construction techniques, new production technologies, for example, the additive manufacturing of gear wheels by selective laser melting, as well as acoustically promising materials (e.g., foam structures or meta-materials) will be part of the analysis. The combination of different lightweight approaches will lead to new possible design concepts for gearboxes. The potential and risks of these cutting-edge designs will be benchmarked against the best-available current systems.