Michell truss design for lightweight gear bodies

A new method for lightweight gear design based on Michell Trusses Design method was investigated in this research to compare with the traditional Topology Optimization method. A workflow with detailed steps was established using example of constructing Michell Trusses to make lightening holes at the gear's web. In this workflow, Michell Trusses are generated from a set of concentric circles. By solving the equation with the variables of concentric circles (complexity), the optimal orthogonality of trusses can be determined. Real experiments were conducted to compare the two design methods in the aspects of design costs and product mechanical property, including recording the time consumed in each link and detecting the force of failure of gears by a testing platform. The results indicate that this new method can significantly reduce design time while maintain the same power-to-weight ratio as the Topology Optimization design, which potentially provide a new research direction for lightweight structural modeling in mechanical engineering and aviation industry. The experimental product developed in this research demonstrated the promising prospects for real world applications.