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Team 51

Team Members

Faculty Advisor

Jay Shah
Gabriel Duncan
Steven Shtern

Julián Norato

Sponsor

Sikorsky Aircraft Corporation

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Torsionally Compliant Gear for Torque Split Gearbox (Phase 2)

The objective of this project is to utilize topology optimization to produce a torsionally compliant yet radially stiff spur gear web geometry. The goal is to produce at least 3 degrees of torsional displacement while limiting the radial displacement to 0.005". This is accomplished with the Structural Optimization feature in Ansys Workbench with an objective of maximizing torsional compliance. Boundary conditions include a fixed gear hub and an applied force on one of the gear teeth, and the constraints consist of a maximum stress, maximum radial displacement, mass retention range, and cyclic symmetry. Upon producing a feasible result, the stress and displacement values are evaluated using Ansys Static Structural. These simulations are compared to an existing model to validate the effectiveness of the computer-generated geometry. Both designs are also 3D printed and compared experimentally through physical testing with a test rig, hydraulic press, load cell, and dial indicator. Implementing an effective design will produce the next generation of split torque gearbox that is lighter, more compact, and involves fewer components.