Optimization design of helical gear spoke structure based on variable density method

A topology optimization of a reducer’s helical gear was performed using the variable density method, with element density as the design variable, compliance as the objective, and constraints on volume fraction and structural equilibrium. The optimized geometry reduced mass by 25% while maintaining sufficient stiffness and strength. Static and modal analyses confirm that the design meets mechanical requirements and achieves the lightweighting goal. This approach demonstrates strong engineering applicability and provides a reference for similar component designs.