ORCID Identifier(s)

ORCID 0000-0001-5353-9518

Graduation Semester and Year

Summer 2025

Language

English

Document Type

Dissertation

Degree Name

Doctor of Philosophy in Mechanical Engineering

Department

Mechanical and Aerospace Engineering

First Advisor

Shuo Linda Wang

Abstract

Hypoid gears represent one of the most generalized and complex forms of gearing, widely used for power transmission of skew shafts in vehicles, aviation, and marine transmission applications. Optimizing their performance remains challenging due to the complex tooth surface and contact behavior. Specifically, the design parameters of the tooth surface are multi-scale, interdependent, and subject to strong constraints, leading to strong nonlinearity and an ill-conditioned Jacobian matrix in the parameter identification model. Moreover, feasible and insensitive contact conditions are difficult to constrain due to the inherent complexity of local conjugate contact between the meshing surfaces. These challenges significantly increase optimization complexity, and to date, no representative dynamic optimization model has been established. This dissertation aims to develop a comprehensive and reliable multi-objective optimization framework for hypoid gears, addressing the limitations of the current models in design parameters identification and contact performance optimization, and ultimately, for the first time, developing an effective dynamic performance optimization model. We proposed a novel identification model based on non-uniform discretization to accurately and efficiently determine machine and tool settings corresponding to the desired tooth surface. Once the relationship between design parameters and the optimal surface is established, a robust contact optimization model is developed by formulating practical and solvable constraints for local conjugate contact through ease-off topography, incorporating uncertain tooth form errors. This optimization model is then extended to the dynamic domain, yielding a holistic and reliable dynamic optimization model to minimize the dynamic response while ensuring gear durability. The influence of boundary conditions on both contact and dynamic performance is also examined, offering valuable insights into optimization modeling schemes. The proposed framework has immediate applicability to other mechanisms kinematically constrained to obey conjugate action and provides a foundation for broader research directions, including lubrication, tribology, and contact fatigue life.

Keywords

Gear, Hypoid gear, Optimization, Contact, Dynamics, Mesh stiffness

Disciplines

Acoustics, Dynamics, and Controls | Applied Mechanics | Computer-Aided Engineering and Design | Manufacturing

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