Multi-objective optimization of gear tooth profiles to improve weight, efficiency, dynamic behavior, and wear performance, focusing on both involute macro-geometry and free-form non-involute profiles. Key results include more than 40% reduction in power losses and 35% reduction in vibration RMS for optimized involute gears. For free-form gears, reductions of up to 55% in average wear depth and 70% in maximum wear depth have been achieved.
MD-Lab research on gear dynamics develops reduced-order, nonlinear and optimization-ready simulation models for spur gear transmissions. The work connects static and dynamic transmission error, load-dependent mesh stiffness, intermittent contact, tooth eigenvibrations, macro-geometry optimization and high-pressure-angle gear design.
MD-Lab develops modelling, simulation, testing and optimization workflows for wet friction clutches, connecting hydrodynamic lubrication, drag-torque losses, engagement dynamics, groove topology, disc-clearance variability and data-driven uncertainty assessment.
Research on plastic gear transmissions at MD-Lab combines material-model development, finite-element and neural-network surrogate modelling, dynamic/NVH simulation, and additive manufacturing technologies. Key results include neural-network surrogates that reproduce finite-element static transmission error curves for polymer gears with 0.49% MAPE, dynamic simulations showing reduced vibration levels compared with metallic gearsets, and additive-manufacturing studies that quantify FDM and other 3D-printing accuracy limits while investigating wear resistance and wear patterns in printed gears.
MD-Lab investigates engineered surface textures for tribological performance, combining bio-inspired hydrodynamic design, CFD-based flow analysis, EDM-induced roughness control, nanostructuring, wettability modification and dry/wet friction testing.
MD-Lab research on coaxial magnetic gears develops fast analytical and hybrid electromagnetic models for torque prediction, topology evaluation, nonlinear dynamic response and eddy-current loss estimation. The work supports the design of contactless transmissions with reduced wear, low noise, inherent overload protection and computationally efficient early-stage optimization.
MD-Lab research on 3D-printed gears studies how additive manufacturing changes both gear design and gear metrology. The work combines free-form tooth-flank optimization for improved wear resistance with CMM-based dimensional accuracy assessment of polymer spur gears produced by FDM, material extrusion and powder bed fusion.
MD-Lab research on double-flank roll testing converts a fast industrial gear inspection method into a richer diagnostic tool. The work links radial composite error measurements with numerical simulation of free-form meshing gears and inverse models for identifying gear-parameter deviations.
MD-Lab research on external heat engines develops design-oriented thermodynamic models for Stirling and Ericsson machines. The work focuses on transient heat transfer, real-cycle losses, valve timing and experimentally grounded performance prediction for engines that can use external heat sources such as waste heat, solar thermal energy, biomass and combustion outside the working volume.
MD-Lab research on geometric dimensioning and tolerancing connects ISO GPS specification, functional performance, datum-system design, finite-element assembly behaviour and inspection strategy for compliant parts and additive-manufactured components.
