Four-parametric design study of the bending strength of circular-fillet versus trochoidal-fillet in gear tooth design using BEM

Circular fillet pinions are designs of superior bending strength evolved as substitutes to the standard trochoidal fillet design. However this has only been verified considering gears of nominal thickness coefficient and addendum. This paper makes a comparative four-parametric study of the achieved bending strength of the two designs (circular fillet/trochoidal fillet) taking into consideration the large range of pinion and gear numbers used in engineering practice. The results are calculated using an automated BEM process and presented in generalised diagrams, called 'stress maps', which are used to observe optimal application and usage restrictions of each design.