Project Title: Investigation of a New Spur Gear Design Based on Composite Material Using an Advanced Tooth Contact Analysis Approach

Project Goal:

The goal of this project is to develop and validate the design of a cylindrical gear transmission based on composite material using an improved tooth contact analysis (TCA) method to optimize the performance and durability of gear systems. By evaluating and refining tooth contact profiles specifically for composite materials, the project aims to address issues such as alignment sensitivity, noise reduction, and wear resistance. The expected outcome is a comprehensive assessment of composite gears as a viable, cost-effective alternative to traditional steel gears, answering the central question of how composite materials can enhance the efficiency, reliability, and service life of gear transmissions in industrial applications.

Objectives:

1.General Objective:

This comprehensive project includes a series of interrelated tasks aimed at revolutionizing spur gear design through the integration of composite materials with advanced analytical methods. The main goal is to enhance gear performance by applying a novel tooth contact analysis method specifically developed for composite-based gears. This approach will address critical aspects such as stress distribution, misalignment sensitivity, and wear behavior. By refining gear design with composite materials, the project seeks to deliver a lightweight, cost-effective, and high-strength alternative to traditional metal gears for diverse industrial applications.

2.Material Selection and Initial Simulation:

The project introduces several key innovations to achieve this goal. First, a rigorous material selection process will assess composites such as epoxy resin and silicon carbide, chosen for their superior strength-to-weight ratio. Selected materials will undergo detailed mechanical testing to verify performance metrics such as tensile strength, elasticity, and wear resistance—providing the foundation for designing gears tailored to the specific properties of the composite. A 3D model of the composite gear will then be developed, followed by Finite Element Analysis (FEA) to evaluate stress distribution and load-bearing capacity. FEA modeling will facilitate preliminary design improvements, ensuring that the gear can withstand target loads without compromising its lightweight advantages.

3.Development of an Advanced Tooth Contact Analysis Method:

The creation of an enhanced tooth contact analysis (TCA) method forms the core of this project, with a specialized approach tailored for analyzing composite materials under various operating conditions. This TCA method will assess tooth contact patterns and account for composite-specific issues such as material anisotropy and alignment sensitivity. Through parametric analysis, the method will evaluate how misalignment affects composite gears differently from conventional metallic counterparts, refining the design for optimal durability and performance. The method will generate a comprehensive dataset on contact path behavior, improving fault diagnosis and misalignment prediction capabilities.

4.Prototype Fabrication and Performance Testing:

Prototype fabrication and performance testing are integral to validating both the TCA method and the composite gear design. A prototype will be manufactured using the selected composite materials, followed by extensive testing under controlled conditions to measure load capacity, vibration, noise, and wear rate. Empirical test data will be compared with FEA and TCA results to provide a clear assessment of the practical feasibility and industrial readiness of the composite gear.

5.Data Analysis and Optimization:

Finally, the project will focus on data analysis and optimization, refining both the TCA model and gear design based on prototype performance characteristics. This phase will ensure that the gear meets all performance benchmarks, minimizing noise, vibration, and wear to target levels. Upon completing these optimizations, the project will reach  Technology Readiness Level (TRL) 1 , with the current readiness level being  TRL 0 .

Project Concept:

The use of composite materials in gear manufacturing offers a promising solution for weight reduction, cost efficiency, and performance improvement—particularly in sectors where mass reduction is critical, such as automotive and aerospace industries. Composite gears, typically made of carbon-fiber- or glass-fiber-reinforced polymers, provide substantial advantages over traditional metals, including superior strength-to-weight ratio, wear resistance, and durability under varying loads.

However, the unique mechanical characteristics of composites, such as anisotropy and misalignment sensitivity, require specialized analytical methods to ensure performance reliability and stability. This project proposes an advanced tooth contact analysis method specifically designed for composite materials.

This new TCA approach enables a comprehensive evaluation of contact paths, accurately assessing transmission characteristics, alignment sensitivity, and wear potential inherent to composite drives. By analyzing parametric contact behavior specific to composites, the method facilitates optimization and alignment correction of tooth surface profiles—essential for reducing noise, vibration, and material degradation in composite transmission systems.

Combining composite materials with this specialized tooth contact analysis approach establishes a robust foundation for developing lighter, more cost-effective, and high-performance gears. The project demonstrates the potential of integrating composite materials with advanced contact analysis methods, paving the way for more efficient, resilient, and reliable gear designs across various industrial applications.

Expected Results:

— At least 3 (three) research articles and/or reviews published in peer-reviewed scientific journals indexed in Science Citation Index Expanded (SCIE) and belonging to the 1st, 2nd, or 3rd quartile by impact factor in the Web of Science database and/or having a CiteScore percentile of at least 60 in  Scopus ;

  and at least  2 (two)  research articles or reviews published in peer-reviewed international or national journals  recommended by the Committee for Quality Assurance in Education and Science (COXVO) .

One of the articles must have a  “multidisciplinary”  classification (for multidisciplinary or interdisciplinary practical applications).

Alternatively: At least  2 (two)  articles and/or reviews in peer-reviewed scientific journals indexed in  SCIE  and belonging to the  1st or 2nd quartile  by impact factor in  Web of Science  and/or having a  CiteScore percentile of at least 70  in  Scopus  and at least  2 (two)  articles or reviews in peer-reviewed international or national journals recommended by  COXVO. One of the articles must have a  “multidisciplinary”  classification.

Alternatively: At least  1 (one)  article or review in a peer-reviewed scientific journal indexed in  SCIE , ranked in the  1st quartile  in  Web of Science , or having a  CiteScore percentile of at least 90  in  Scopus and at least  1 (one)  article or review in a peer-reviewed international or national journal recommended by  COXVO . One of the articles must have a  “multidisciplinary”  classification. In addition, at least  1 (one) PhD candidate  specializing in the corresponding research field is expected to prepare and defend a dissertation  during the project implementation period or no later than two (2) years after its completion .