Neural Network-Based Estimation of Gear Safety Factors from ISO-Based Simulations

Digital Twins (DTs) have become essential tools for the design, diagnostics, and prognostics of mechanical systems. In gearbox applications, DTs are often built using physics-based simulations guided by ISO standards. However, standards-based approaches may suffer from complexity, licensing limitations, and computational costs. The concept of symmetry is inherent in gear mechanisms, both in geometry and in operational conditions, yet practical applications often face asymmetric load distributions, misalignments, and asymmetric and symmetric nonlinear behaviors. In this study, we propose a hybrid method that integrates data-driven modeling with standard-based simulation to develop efficient and accurate digital twins for gear transmission systems. A digital twin of a spur gear transmission is generated using KISSsoft®, employing ISO standards to compute safety factors across varied geometries and load conditions. An automated MATLAB-KISSsoft® (COM-interface) enables large-scale data generation by systematically varying key input parameters such as torque, pinion speed, and center distance. This dataset is then used to train a neural network (NN) capable of predicting safety factors, with hyperparameter optimization improving the model’s predictive accuracy. Among the tested NN architectures, the model with a single hidden layer yielded the best performance, achieving maximum prediction errors below 0.01 for root and flank safety factors. More complex failure modes such as scuffing and micropitting exhibited higher maximum errors of 0.0833 and 0.0596, respectively, indicating areas for potential model refinement. Comparative analysis shows strong agreement between the NN outputs and KISSsoft® results, especially for root and flank safety factors. Performance is further validated through sensitivity analyses across seven cases, confirming the NN’s reliability as a surrogate model. This approach reduces simulation time while preserving accuracy, demonstrating the potential of neural networks to support real-time condition monitoring and predictive maintenance in gearbox systems.