A Hybrid AI-Driven Knowledge-Based Expert System for Optimizing Gear Design: A Case Study for Education

This paper presents a hybrid knowledge-based expert system (KBES) designed to predict crack incubation and fatigue life in gear design, serving as both a research tool and an educational resource. While crack growth and initiation are well understood, crack incubation remains a challenging area. The presented expert system (KBES) integrates a novel mathematical model for crack incubation based on analogy and defect analysis principles with an optimization algorithm for gear design. The system uses genetic algorithms to optimize gear parameters, demonstrating a 5–10% deviation from experimental values in a specific gear design problem case study. Based on this KBES and a hybrid approach, we developed a learning environment based on an intelligent tutoring system (ITS) which serves older students (MSc and PhD) as a learning environment for the acquisition of knowledge and, above all, for the development of an in-depth understanding of the phenomena that occur both during incubation and initialization and during the further propagation of cracks in the root of the gear tooth, which is the basis for determining the lifespan of gear transmissions.