Abstract
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.