Selective Laser Melting of a Ti-6Al-4V Lattice-Structure Gear: Design, Topology Optimization, and Experimental Validation
The manufacture of lightweight components is one of the most important requirements in the automotive and aerospace industries. Gears, on the other hand, are among the heaviest parts in terms of their total weight. Accordingly, a spur gear was considered, the body of which was configured as a lattic...
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MDPI AG
2025-07-01
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| author | Riad Ramadani Snehashis Pal Aleš Belšak Jožef Predan |
| author_facet | Riad Ramadani Snehashis Pal Aleš Belšak Jožef Predan |
| author_sort | Riad Ramadani |
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| description | The manufacture of lightweight components is one of the most important requirements in the automotive and aerospace industries. Gears, on the other hand, are among the heaviest parts in terms of their total weight. Accordingly, a spur gear was considered, the body of which was configured as a lattice structure to make it lightweight. In addition, the structure was optimized by topology optimization using ProTOP software. Subsequently, the gear was manufactured by a selective laser melting process by using a strong and lightweight material, namely Ti-6Al-4V. This study defeated the problems of manufacturing orientation, surface roughness, support structure, and bending due to the high thermal gradient in the selective laser melting process. To experimentally investigate the benefits of such a lightweight gear body structure, a new test rig with a closed loop was developed. This rig enabled measurements of strains in the gear ring, hub, and tooth root. The experimental results confirmed that a specifically designed and selectively laser-melted, lightweight cellular lattice structure in the gear body can significantly influence strain. This is especially significant with respect to strain levels and their time-dependent variations in the hub section of the gear body. |
| format | Article |
| id | doaj-art-2451adb46ce64acea48241ca3d628a31 |
| institution | DOAJ |
| issn | 2076-3417 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj-art-2451adb46ce64acea48241ca3d628a312025-08-20T02:45:53ZengMDPI AGApplied Sciences2076-34172025-07-011514794910.3390/app15147949Selective Laser Melting of a Ti-6Al-4V Lattice-Structure Gear: Design, Topology Optimization, and Experimental ValidationRiad Ramadani0Snehashis Pal1Aleš Belšak2Jožef Predan3Faculty of Mechanical Engineering, University of Prishtina, Rr. Agim Ramadani, Ndërtesa e Fakulteteve Teknike, 10000 Prishtina, KosovoFaculty of Chemistry and Chemical Engineering, University of Maribor, Smetanova 17, 2000 Maribor, SloveniaFaculty of Mechanical Engineering, University of Maribor, Smetanova 17, 2000 Maribor, SloveniaFaculty of Mechanical Engineering, University of Maribor, Smetanova 17, 2000 Maribor, SloveniaThe manufacture of lightweight components is one of the most important requirements in the automotive and aerospace industries. Gears, on the other hand, are among the heaviest parts in terms of their total weight. Accordingly, a spur gear was considered, the body of which was configured as a lattice structure to make it lightweight. In addition, the structure was optimized by topology optimization using ProTOP software. Subsequently, the gear was manufactured by a selective laser melting process by using a strong and lightweight material, namely Ti-6Al-4V. This study defeated the problems of manufacturing orientation, surface roughness, support structure, and bending due to the high thermal gradient in the selective laser melting process. To experimentally investigate the benefits of such a lightweight gear body structure, a new test rig with a closed loop was developed. This rig enabled measurements of strains in the gear ring, hub, and tooth root. The experimental results confirmed that a specifically designed and selectively laser-melted, lightweight cellular lattice structure in the gear body can significantly influence strain. This is especially significant with respect to strain levels and their time-dependent variations in the hub section of the gear body.https://www.mdpi.com/2076-3417/15/14/7949topology optimizationlaser powder bed fusionTi6Al4Vlattice structuregear test rigstrain measurement |
| spellingShingle | Riad Ramadani Snehashis Pal Aleš Belšak Jožef Predan Selective Laser Melting of a Ti-6Al-4V Lattice-Structure Gear: Design, Topology Optimization, and Experimental Validation Applied Sciences topology optimization laser powder bed fusion Ti6Al4V lattice structure gear test rig strain measurement |
| title | Selective Laser Melting of a Ti-6Al-4V Lattice-Structure Gear: Design, Topology Optimization, and Experimental Validation |
| title_full | Selective Laser Melting of a Ti-6Al-4V Lattice-Structure Gear: Design, Topology Optimization, and Experimental Validation |
| title_fullStr | Selective Laser Melting of a Ti-6Al-4V Lattice-Structure Gear: Design, Topology Optimization, and Experimental Validation |
| title_full_unstemmed | Selective Laser Melting of a Ti-6Al-4V Lattice-Structure Gear: Design, Topology Optimization, and Experimental Validation |
| title_short | Selective Laser Melting of a Ti-6Al-4V Lattice-Structure Gear: Design, Topology Optimization, and Experimental Validation |
| title_sort | selective laser melting of a ti 6al 4v lattice structure gear design topology optimization and experimental validation |
| topic | topology optimization laser powder bed fusion Ti6Al4V lattice structure gear test rig strain measurement |
| url | https://www.mdpi.com/2076-3417/15/14/7949 |
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