Optimization of asymmetric spur gear drives for maximum bending strength using direct gear design method

Two procedures to optimize a given asymmetric gear drive have been developed through direct gear design method. Considering several sets of the addendum pressure angles of pinion and gear for a required contact ratio, first the nonstandard rack cutters and subsequently the asymmetric tooth profiles of pinion and gear are generated for each set. FEM analysis has been carried out to determine maximum fillet stress in pinion and gear at each set. The set. of profiles that develops an equal and possible lowest minimum of the maximum fillet stress at its respective fillet is considered as the optimum one for a maximum load carrying capacity. In this connection, the influence of speed ratio, asymmetric factor, number of teeth, and center distance on the maximum fillet stress is also studied.