Topology Optimization of Spur Gear

This study presents the analysis and topology optimization of a spur gear to achieve material reduction while maintaining structural performance. Initially, gear analysis is carried out to evaluate deformation under given loading conditions. Different optimized designs such as hybrid hole, radial spoke and circular perforated structures were analysed and compared. The best design was selected by comparing minimum deformation with the original gear. The results show that weight can be reduced without affecting strength, making the gear more efficient and suitable for practical applications.