Topology optimization and additive manufacturing in producing lightweight and low vibration gear body

Reducing gear vibration as well as its weight is a challenging field latterly. This research deals with the manufacturing of a gear having cellular lattice body structure by using Selective Laser Melting (SLM) technology. A cellular lattice design defines a complex structure which typically cannot be fabricated by conventional manufacturing technologies. On the other hand, the SLM technology enables the production of such complex cellular lattice structures directly from their computer-aided designed (CAD) models. The cellular gear body structure was designed and optimized by employing topology optimization software ProTOp and fabricated by SLM using Ti-6Al-4V alloy. The problems faced by the researchers and the solution which enabled the manufacturing of this gear by SLM are described in this paper. To estimate the performance of the gear during operation, the sound pressure was measured and compared to the results obtained with the gear having a solid body. The experimental results show that the investigated cellular lattice structure of the gear body is well capable to reduce the mass and vibration of the gear.