Rohit Kumar
Independent Researcher
India
Abstract
Finite Element Analysis (FEA) has become an indispensable tool in gear design, enabling precise evaluation of stress distribution under various loading conditions. This manuscript presents a comprehensive study of stress distribution in spur gears using FEA tools available up to 2016, such as ANSYS Mechanical and ABAQUS Standard. The work encompasses model creation, mesh convergence studies, material property selection, loading and boundary condition definition, and result interpretation. Two industrial case studies—a medium-duty steel gear pair in automotive transmission and a high-precision brass gear for instrumentation—are examined. Research gaps in mesh optimization, contact modeling fidelity, and fatigue life estimation are identified. The study’s methodology details geometry import, meshing strategies, contact definitions, and post-processing metrics. Results reveal peak von Mises stresses at gear tooth fillets, with values correlating strongly to gear geometry and mesh density. The conclusion underscores best practices for FEA setup in spur gear analysis and recommends future work on dynamic loading and non-linear material behavior. Ten key references (≤ 2016) support the discussion.
Keywords
Finite Element Analysis, Spur Gears, Stress Distribution, Gear Tooth Fillet, Mesh Convergence, Contact Modeling
References
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