Design, Analysis, Optimization and Validation of Three Stage Helical Gearbox: Computational Approach

Abstract

This research present a comprehensive design, analysis, optimization, and validation of a triple stage helical reduction gearbox, addressing the limited exploration of three stage configurations compared to extensively studied single and double stage systems. Triple stage gearboxes offer enhanced reduction capabilities but pose challenges related to transmission vibrations, stress concentration and structural integrity. An existing gearbox model was examined to identify root causes of failure through detailed structural and vibrational analysis. Based on these findings, design modifications were introduced and optimized using advanced computational methods to minimize equivalent stresses and total deformation. The optimized model demonstrated significant improvements under defined loading conditions, with the curved top casing design (structural steel, 9 mm thickness) achieving an 80. 3% reduction in stress and a 97. 2% reduction in deformation compared to the baseline configuration. In contrast, the fully curved casing exhibited no substantial performance gain over the original design. Validation through numerical and mathematical approaches confirmed the reliability of optimized configuration. The results emphasize the potential of advanced design and optimization strategies to enhance efficiency, vibration control, and durability in triple stage gearboxes, contributing to innovation in industrial applications and gearbox technological development.