A computer-aided methodology that applies the Finite Element Method (FEM) to gear design is presented in this work. The analysis takes into account the real tooth profile created by the involute flank of the tooth and the trochoidal fillet at the bottom of the tooth. The method enables gears with modified addendum and with any number of teeth to be modeled, so it can be used in CAD systems that require accurate models. Finally, the design process uses finite element modeling as an analysis tool to study the behaviour of components or products before they physically exist, thereby eliminating the need to create physical prototypes and providing a clean engineering design process.
The basic weakness of plastic spur gear teeth is tooth fracture brought on by the accumulation of stress at the root of the tooth and by the geometry of the tooth. Tooth width and height play a major role in failure, as does the Lewis factor, which has a direct effect on the expression to calculate tooth strength. This study describes a theoretical analysis of a procedure to determine the Lewis factor for asymmetric teeth.
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