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Multi-Objective Optimization of the Geometry of a Modular Friction Disk Cutter for Thermo-Friction Processing of Spur Gear Teeth

А. Д. СулейменовFaculty of Mechanical Engineering, Toraighyrov University, Pavlodar 140008, KazakhstanКарибек ШеровEducational Program Group “Mechanics and Metalworking”, Institute of Engineering and Food Technology, S. Seifullin Kazakh Agrotechnical Research University, Astana 010000, KazakhstanAssylbek KassenovFaculty of Mechanical Engineering, Toraighyrov University, Pavlodar 140008, KazakhstanA. V. MazdubayFaculty of Mechanical Engineering, Toraighyrov University, Pavlodar 140008, KazakhstanJamshid RavshanovDepartment Mechanical Engineering, Faculty of Energy and Mechanics, Navoi State University of Mining and Technology, Navoi 210100, UzbekistanDoniyor IsaevDepartment Mechanical Engineering, Faculty of Energy and Mechanics, Navoi State University of Mining and Technology, Navoi 210100, UzbekistanMusurmon JuraevDepartment of Mechanical Engineering Technology, Faculty of Energy and Mechanical Engineering, Almalyk Branch of Tashkent State Technical University, Almasy 110100, UzbekistanGulerke TattimbekDepartment of Technological Equipment, Mechanical Engineering and Standardization, Abylkas Saginov Karaganda Technical University, Karaganda 100027, KazakhstanSayagul TussupovaFaculty of Mechanical Engineering, Toraighyrov University, Pavlodar 140008, KazakhstanDavran RadjibaevFaculty of Railway Transport Engineering, Tashkent State Transport University, Tashkent 100167, UzbekistanZhanara MussinaFaculty of Mechanical Engineering, Toraighyrov University, Pavlodar 140008, Kazakhstan

2026en

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Annotatsiya

This study presents multi-objective geometric optimization of a modular friction disk cutter for spur gear thermo-friction processing within the ANSYS Workbench 2024 R1. The integrated workflow—Geometry → Steady-State Thermal → Static Structural → Design of Experiments → Response Surface → Response Surface Optimization—enables selection of a rational tool geometry within a single parametric model. Variable dimensions (a, b, c) describe the load-bearing part: a characterizes the transitional thin profile zone, b is the massive supporting part, and c is the intermediate disk thickness controlling thermo-mechanical load transmission. Dimension c most significantly influences equivalent stresses and directional deformation, while maximum temperature depends on combined a and c effects. Based on Response Surface Optimization, the rational solution domain is concentrated near a≈3 mm, b≈10 mm, and c≈4 mm, yielding P4≈33.306 MPa, P5≈295.93 °C, and P6≈−5.7488·10−5 m. These values demonstrate a sufficient calculated safety margin within the finite element framework, providing a technically justified direction for prototype manufacturing. Although currently evaluated as purely computational without direct full-scale physical measurements, these results establish a foundation for subsequent experimental validation using thermal imaging and optical deformation analysis. Future research will focus on transient thermo-mechanical modeling with impulse cooling and experimental verification.

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DOI: 10.3390/jmmp10070235

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