Optimal design of a multi-speed gearbox involves different types of decision variables and objectives. Due to lack of efficient classical optimization techniques, such problems are usually decomposed into tractable subproblems and solved. Moreover, in most cases the explicit mathematical expressions of the problem formulation is exploited to arrive at the optimal solutions. In this paper, we demonstrate the use of a multi-objective evolutionary algorithm, which is capable of solving the original problem involving mixed discrete and real-valued parameters and more than one objectives, and is capable of finding multiple nondominated solutions in a single simulation run. On a number of instantiations of the gearbox design problem having different complexities, the efficacy of NSGA-II in handling different types of decision variables, constraints, and multiple objectives are demonstrated. A highlight of the suggested procedure is that a post-optimal investigation of the obtained solutions allows a designer to discover important design principles which are otherwise difficult to obtain using other means.

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