Parametric Study of Contact Stress in Spur Gears Using Analytical and FEA Approaches
K Anil Kumar,
Dr. K R Yellu Kumar,
L Balusubramanayam,
N Karthikeyan
Contact stress on spur gears is one of the most significant aspects that define their performance,
durability, and failure characteristics. Pitting, wear, and premature failure of gear teeth can be the
result of excessive contact stress. This paper provides an in-depth examination of contact stresses in a
spur gear system through theoretical modeling of contact stresses through the Hertzian contact theory
and finite element analysis (FEA). Parameters are taken to be gear material properties, gear module,
angle of pressure and load distribution to assess the maximum contact stress at the surfaces of the teeth.
The findings reveal the impact of the gear geometry and operating load on the distribution of stresses
and determine the areas that are prone to failure. This study, through the comparison of analytical and
numerical methods, gives a detailed picture of the stress patterns in spur gears, which can be used to
guide improved design of spur gears and the choice of materials to improve reliability and life cycle. The
ultimate goal of the study is to optimise gear performance at different operating conditions.
