Optimization of the design of an external gear pump casing and efficiency through structural finite element analysis and using response surface methodology

In this study, we present an improvement in the external gear pump casing by reducing its weight, aiming to minimize the material used in manufacturing while maintaining casing stiffness and increasing the efficiency to mass ratio. The finite element method (FEM) was employed using ANSYS Workbench to analyze the pump casing under operating pressure, allowing for the calculation of stress and deformation. The geometric model of the pump casing was created using SolidWorks, where we linked its dimensions to a single reference parameter using the equation tool. This approach facilitated the optimization process without altering the original design. The optimization analysis was conducted using the Response Surface Methodology (RSM), based on the results obtained. The study led to an optimal design that balances lightweight characteristics with structural strength. A weight reduction of 9.5% was achieved compared to the original design, with a maximum recorded deformation of 0.031 mm and a maximum stress of 127 MPa, resulting in a safety factor of 3, demonstrating the strength and robustness of the optimal design. Additionally, the efficiency to mass ratio was calculated for both the original and optimized designs. The optimized design achieved a value of 8.8, compared to 7.9 for the original, highlighting the enhanced performance and efficiency of the optimal design.