The deterministic numerical optimization algorithm COBYLA is applied to minimize the vibrational level of a gearbox. In previous papers, gearboxes are most often modeled by simple rectangular boxes if they are numerically optimized. In this paper, however, a rather realistic FE model of a gearbox is presented, which includes flanges and bearing bores. The thickness distribution of predefined modification domains is optimized by a sequence of iteratively repeated FE analyses and objective function evaluations so as to minimize the mean level of structure borne sound in the frequency range 0-1000 Hz, subject to suitable constraints. Due to the size of the FE model (about 17000 nodes and 51200 DOFs) and to the huge number of design variables and constraints (821 and 1643, respectively), this constitutes a rather challenging optimization problem that requires enormous computation times. As a result of the optimization, the mean level of structure borne sound is reduced by 5.7 dB (-73%), whereas the structural mass does not increase.
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