• CN: 11-2187/TH
  • ISSN: 0577-6686

Journal of Mechanical Engineering ›› 2026, Vol. 62 ›› Issue (11): 171-190.doi: 10.3901/JME.260591

Previous Articles    

High-power-density Design Method for Aeroengine Gear Systems via Replacing Steel with Plastic

LU Zehua1,2, WANG Qiao3, LIU Huaiju1, WANG Zhongrong3, ZHANG Yangming1   

  1. 1. State Key Laboratory of Mechanical Transmissions for Advanced Equipment, Chongqing University, Chongqing 400030;
    2. College of Aerospace Engineering, Chongqing University, Chongqing 400030;
    3. Laboratory of Mechanical Systems Technology, AEEC Sichuan Gas Turbine Establishment, Chengdu 610500
  • Received:2024-12-06 Revised:2025-03-06 Published:2026-07-29

Abstract: A high-power-density design method for aeroengine gear systems by replacing steel with plastic is investigated to address the demands for cost and weight reduction. Durability data for plastic gears under varying temperatures and reliability conditions were collected, through experiments involving oil spray lubrication and elevated oil temperatures, defining accurate strength limits for the conversion from steel to plastic. An optimization model for aeroengine gear systems was developed using an adaptive genetic optimization algorithm, CatBoost surrogate sub-models, and system comprehensive assessment indicators, which improve the power density of a gear transmission in a gas turbine engine from 9.8 kW/kg to 19.6 kW/kg, in coordination with material, geometry, and performance parameters subject to strength, vibration, and structural constraints. This method offers an effective approach for substituting steel with plastics in power transmission systems.

Key words: plastic gears, aeroengine gear systems, high-power-density design, durability data

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