Cost optimization of two-stage helical gearboxes with second stage double gear-sets

In practice, the cost of a gearbox plays a very important role in the trade. Therefore, reducing the cost of gearboxes is an important task not only when manufacturing the gearboxes but also when designing them. In order to reduce the cost of a gearbox, there are many solutions in which determining the optimal partial gear ratios of a gearbox is an effective measure. This is because it not only the size, the mass but also the cost of a gearbox depends greatly on the partial gear ratios. This work presents a method for calculating the cost function of two-stage helical gearboxes with second-stage double gear-sets based on the mass of the components that construct the gearbox. The cost objective function is minimized to achieve the optimal transmission ratios. Furthermore, screening experiments are carried out with nine important input parameters that have significant effects on the optimum transmission ratio of the second stage. These parameters are the total gearbox ratio, the coefficient of wheel face width of the first stage, coefficient of wheel face width of the second stage, the allowable contact stress of the first stage, the allowable contact stress of the second stage, the output torque, the cost of gearbox housing, the cost of gears, and the shaft cost. The experimental results of were analysed by using the Analysis of Variance (ANOVA) method with the help of Minitab 19 software. The results demonstrate that the effective weight of the input parameters and their interactions on the output response was investigated. Also, a regression model for computing the optimal transmission ratio of the second stage was proposed. This brings significance not only in the design process but also in manufacturing since the gearbox cost can decrease