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<p>Helical gears are essential in mechanical systems, requiring precise assessment of bending stresses under dynamic conditions for reliable design. The demand for compact, high-performance, and quieter gearboxes presents challenges in stress analysis, requiring more accurate predictive methods beyond conventional approaches. This study examines the influence of the module on bending stresses in helical gear pairs using experimental, theoretical, and finite element analysis (FEA) approaches. The photostress technique was employed to measure bending stresses, while dynamic loads were calculated using the velocity factor method and Spott’s equation. Finite element analysis modeled and simulated gear dynamics using a commercial solver. Comparative analyses identified discrepancies between theoretical, experimental, and FEA results, quantifying error percentages. Findings reveal notable variations between methods, necessitating a correction factor to improve the accuracy of theoretical predictions. The proposed correction factor aligns estimates from the velocity factor method and Spott’s equation with experimental and FEA results, enhancing reliability. This research offers a framework for optimizing gear design, reducing material usage and costs without compromising strength and performance, with applications across automotive, aerospace, and industrial sectors.</p>

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Optimization and Statistical Analysis of Stress Parameters in Helical Gears Using Taguchi Method and ANOVA

  • 期刊论文

  • 发表日期：

    2025年12月5日

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  • Prashant J. Patil,
  • Mahesh R. Jadhav,
  • Pramod V. Mulik,
  • S. V. Lingaraju,
  • Krishnakumar D. Joshi

摘要

Helical gears are essential in mechanical systems, requiring precise assessment of bending stresses under dynamic conditions for reliable design. The demand for compact, high-performance, and quieter gearboxes presents challenges in stress analysis, requiring more accurate predictive methods beyond conventional approaches. This study examines the influence of the module on bending stresses in helical gear pairs using experimental, theoretical, and finite element analysis (FEA) approaches. The photostress technique was employed to measure bending stresses, while dynamic loads were calculated using the velocity factor method and Spott’s equation. Finite element analysis modeled and simulated gear dynamics using a commercial solver. Comparative analyses identified discrepancies between theoretical, experimental, and FEA results, quantifying error percentages. Findings reveal notable variations between methods, necessitating a correction factor to improve the accuracy of theoretical predictions. The proposed correction factor aligns estimates from the velocity factor method and Spott’s equation with experimental and FEA results, enhancing reliability. This research offers a framework for optimizing gear design, reducing material usage and costs without compromising strength and performance, with applications across automotive, aerospace, and industrial sectors.