Evaluation of Lattice Material Suitability for Additive Manufactured Gears under Compression Loads

Abstract

Lattice structures have gained increasing prominence in modern applications due to their advantageous traits such as lightweightness, energy absorption capacity without compromising strength. Additive manufacturing processes have further facilitated the integration of lattice structures into components and have opened doors for the development of innovative lattice types. This study focuses on the integration of six distinct lattice forms, comprising both strut-based and TPMS lattice types, into gear blanks. The objective is to evaluate their load-bearing capabilities when the gear teeth are subjected to compression loading. Both numerical simulations and experimental investigations were conducted to analyze the behavior of the tooth-blank system under these conditions. The findings indicate that the incorporation of TPMS structures into the gear blank significantly enhances its resistance to external compression loading compared to the strut-based lattice models. This research highlights the potential of TPMS integration to improve component performance and durability with significant weight reductions in the machinery industry, in various manufacturing sectors, where industrial gears are used. It is thought that high-performance components, which will be produced with AM using less material than traditional production methods, will be used more intensively in future industries.