Work

Multi-scale topology optimization of micro-textured gear for interface enriched lubrication and anti-scuffing load-bearing capacity

Year: 2026

Type: article

Abstract: Current research lacks systematic understanding of cross-scale correlations between micro-texture geometry and macro-lubrication behavior. This study presents a multi-scale collaborative optimization methodology for gear micro-textured meshing interface (MTMI). An objective function targeting macroscopic interfacial performance is formulated, and a topology optimization strategy is employed to achieve optimal micro-element texture (MET) configuration. The homogenization analysis captures the modulating effects of MET on interface enriched lubrication (IEL) and stress fields, while topology optimization transcends conventional parametric geometric constraints, enabling the generation of non-regular MET topological patterns tailored to complex operating conditions, thereby ensuring optimal macroscopic anti-scuffing load-bearing capacity (ASLBC). The proposed scheme is validated through numerical simulations of two representative problems capturing distinct lubrication regimes: (1) IEL, characterizing transient load-bearing dynamics governed by temporally evolving MET configurations and (2) ASLBC, elucidating steady-state load-bearing capacity modulation via spatially heterogeneous MET distributions. A Taylor expansion-based surrogate model is developed to efficiently explore the MET configuration design space, significantly enhancing computational efficiency and solution accuracy for multi-scale optimization. While the gradient-based algorithm cannot guarantee local optimality, extensive numerical simulations and cross-validation studies demonstrate consistent convergence toward high-performance MET configurations, with sensitivity analyses of design parameters further confirming the engineering applicability of the optimized solutions.

Source: Advances in Mechanical Engineering

DOI: 10.1177/16878132261464196

Authors: Weiqiang Zou, Xigui Wang, Yongmei Wang, Jiafu Ruan

Institutions: Huaqiao University, Heilongjiang Institute of Technology

Language: English

Topic: Tribology and Lubrication Engineering

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

Open Access status: gold

Estimated APC paid: $2,650

Funder: National Natural Science Foundation of China