Original Article

Proc IMechE Part C:

J Mechanical Engineering Science
Optimization of fillet stress to 2016, Vol. 230(7–8) 1139–1148
! IMechE 2015

enhance the bending strength Reprints and permissions:

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through non-standard high DOI: 10.1177/0954406215602287

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contact ratio spur gears

P Marimuthu and G Muthuveerappan

Abstract
The present study aims to determine the improvement in the bending strength of the non-standard high contact ratio
spur gears based on the balanced (optimum) fillet stress of the pinion and gear. The average number teeth in contact is
more than two for high contact ratio gear drives. In the non-standard high contact ratio spur gears, the rack cutter tooth
thickness factor is more than 0.5, whereas the standard rack cutter tooth thickness factor is 0.5. The maximum fillet
stresses of the pinion and gear is not equal for non-standard high contact ratio spur gear drives when the gear ratio
increases. In order to avoid the fatigue failure of the gear, the fillet stresses of the pinion and gear should be balanced.
This balanced stress is predicted as the optimum fillet stress. Hence, the present study focuses to optimize the fillet
stress with respect to the rack cutter tooth thickness factor of the pinion and gear through finite element analysis. Also, a
parametric study is carried out to obtain the influence of some gear parameters, such as gear ratio, teeth number in the
pinion, pressure angle, addendum height and corrected gear drives (Sþ, S and So) on the optimum fillet stress with
respect to the rack cutter tooth thickness factor of the pinion and gear.

Keywords
Bending strength, high contact ratio, non-standard spur gear, load sharing ratio, fillet stress, rack cutter tooth thickness
factor

Date received: 10 May 2015; accepted: 22 June 2015

Introduction
The modern power transmission drives require higher
load-carrying capacity with less weight and more
compact in size. These requirements can be achieved
through non-standard high contact ratio spur gears.
In the standard high contact ratio (HCR) spur gear,
the rack cutter tooth thickness factor of pinion and
gear is 0.5. But in the case of non-standard HCR spur
gear, the rack cutter tooth thickness factor is not
equal to 0.5 (Figure 1).
Elkholy1 developed an analytical model to deter-
mine the bending and contact stress considering the
tooth load sharing for HCR spur gears and validated
through an experimental (photoelastic method) study.
Liou et al.2 studied the effect of contact ratio on
dynamic load and stated that the dynamic load is
lower for HCR spur gear drives when compared to
normal contact ratio (NCR) gear spur gear drives.
Yildirim and Munro3 developed a systematic
approach to determine the effect of profile relief on
transmission error for both NCR and HCR spur
gears. Rao and Yoon4 proposed a method to reduce
transmission error for helical gears. Mohanty5
developed an analytical model to find the load shar-
ing-based bending and contact stresses. Wang and
Howard6,7 determined the torsional mesh stiffness,
transmission error, tooth root bending stress and con-
tact stress through finite element method with adap-
tive meshing. Senthil Kumar et al.8 optimized the
bending strength of the asymmetric gear with respect
to addendum modifications. Sivakumar et al.9 con-
ducted a case study to replace the NCR spur gear
with HCR spur gear used in the final drive of military
tracked vehicle. Prabhu Sekar and Muthuveerappan10
studied the improvement in the bending strength of a
non-standard NCR spur gear.
It is found that many authors developed experi-
mental and numerical methods to find the bending
Department of Mechanical Engineering, Indian Institute of Technology
Madras, India
Corresponding author:
P Marimuthu, Department of Mechanical Engineering, Indian Institute of
Technology Madras, India.
Email: pmiitm@gmail.com

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1140 Proc IMechE Part C: J Mechanical Engineering Science 230(7–8)

Figure 1. Conventional standard rack cutter.

strength of HCR spur gear drives. But, very limited tooth contact (FHPDTC), second lowest point of
studies are available to improve the bending strength double tooth contact (SLPDTC), second highest
of non-standard HCR spur gear drives. Also, the point of double tooth contact (SHPDTC), and highest
influence of critical gear parameters on the optimum point of tooth contact (HPTC), which are denoted as
fillet stress to improve the bending strength are not A, B, C, D, E, and F, respectively. The triple pair
discussed in detail anywhere. Hence, the present study contact zones are A–B, C–D, and E–F. The first
focuses to optimize the fillet stress with respect to the and second double pair contact zones are B–C and
rack cutter tooth thickness factor of the pinion and D–E, respectively. It is important to determine the
gear through finite element analysis. Also, a paramet- critical loading point for the high quality gear
ric study is carried out to obtain the influence of some design. At this critical loading point, the fillet stress
gear parameters, such as gear ratio, teeth number in is high. The critical loading point for NCR spur gear
the pinion, pressure angle, addendum height and cor- is always the highest point of single tooth contact
rected gear drives (Sþ, S and So) on the optimum (HPSTC), but it occurs at the second double tooth
fillet stress with respect to the rack cutter tooth thick- contact region for HCR spur gears. These critical
ness factor of the pinion and gear. loading points are determined using equations (1)
to (14).
Nonstandard high contact ratio rack qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
cutter rA ¼ ðT1 AÞ2 þ r2b1 ð1Þ
In standard gears, the rack cutter tooth thickness qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
factor of pinion and gear, Sr1 ¼ Sr2 ¼ 0.5 pm and rB ¼ ðT1 BÞ2 þ r2b1 ð2Þ
pitch is pm. In contrast, the non-standard gear
drives have Sr2 6¼ 0.5 pm and the rack cutter tooth qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
thickness factor of pinion, Sr1 ¼ 1  Sr2. In this rC ¼ ðT1 CÞ2 þ r2b1 ð3Þ
work, the rack cutter tooth thickness factor of qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
pinion and gear is determined based on the balanced rD ¼ ðT1 DÞ2 þ r2b1 ð4Þ
maximum fillet stress. The standard and non-standard
high contact ratio of basic rack cutter is shown in qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
Figures 1 and 2, respectively. rE ¼ ðT1 EÞ2 þ r2b1 ð5Þ

Line of action for non-standard HCR spur gears rF ¼ ra1 ð6Þ

qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
Figure 3 shows the contact position of the non-
AF ¼ r2a1  r2b1 þ r2a2  r2b2  ao sin o ð7Þ
standard HCR spur gear. In HCR gear drives, the
typical loading points of the pinion are lowest point
of tooth contact (LPTC), first lowest point of double T1 T2 ¼ ao  sin o ð8Þ
tooth contact (FLPDTC), first highest point of double

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Marimuthu and Muthuveerappan 1141

Figure 2. Nonstandard high contact ratio rack cutter of gear.

Figure 3. Line of action for non-standard HCR spur gear (Sr2 ¼ 0.58).

T1 A ¼ T1 F  AF ð9Þ The gear parameters considered for this are listed in

the Table 1. This 2D solid model exactly simulates the
T1 B ¼ T1 F  2  pb ð10Þ gear generated using hob cutter. The coordinate
points of the involute and trochoid are obtained
T1 C ¼ T1 A þ pb ð11Þ through parametric equations to develop the non-
standard HCR spur gear. The Ansys parametric
T1 D ¼ T1 F  pb ð12Þ design language (APDL)11 is developed for this
study. A six-nodded triangular element (in ANSYS,
T1 E ¼ T1 A þ 2  pb ð13Þ
2D-PLANE 82) with two degrees of freedom at each
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi node is selected to develop the finite element model.
T1 F ¼ r2a1  r2b1 ð14Þ The contact and critical fillet region is discretized as a
fine mesh based on the convergence study. A standard
contact is established between the pinion and gear.
The pinion surface is defined as the contact surface
Finite element modeling of non-standard (CONTA172) and the gear surface as target
(TARG169). For boundary conditions and loading,
HCR spur gears the inner periphery of the gear is restrained in all
Figure 4 shows the two dimensional (2D) five teeth directions and normal force, Fn ¼ 10 N with equiva-
full rim model of the non-standard HCR spur gears. lent torque applied clockwise at the inner periphery

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1142
Figure 4. Finite element model of non-standard HCR spur gear (m ¼ 1 mm, z1 ¼ 40, i ¼ 1.5, a ¼ 20 , sr2 ¼ 0.48, " ¼ 2.2, x1 ¼ 0,
x2 ¼ 0, ha ¼ 1 m, hf ¼ 1. 3 m). (a) 2D-Five teeth full rim model and (b) magnification at A.
Table 1. Gear parameters.
Parameters
Module, m (mm)
Pressure angle, a
Number of teeth in pinion, z1
Gear ratio
Addendum factor, ha
Dedendum factor, hf
Contact ratio, "
Addendum modification factor, x
Rim thickness (mm)
Face width, b (mm)
Normal force, Fn (N)
Rack cutter type
of the pinion. The material model for this study is
linear elastic, isotropic and homogeneous with an elas-
tic constant E ¼ 210 GPa and Poisson’s ratio g ¼ 0.3.
Also, the FE model has the following assumptions.
1. The error in the tooth profile is neglected.
2. The backlash is assumed to be zero.
3. The maximum stresses are estimated based on the
assumption of plain strain condition.
4. The friction is neglected to make a standard con-
tact between the pinion and gear surface.
Results and discussion
Load sharing ratio
The determination of load sharing ratio (LSR) is
important in high contact ratio gears for effective
design. It is defined as the contact load (Fni) taken
by the individual tooth pair at the instantaneous
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Proc IMechE Part C: J Mechanical Engineering Science 230(7–8)
position to the total normal load (Fn) acting on the
gear tooth (equation (15)). The LSR is plotted for a
Value two different rack cutter tooth thickness factor of gear
(sr2 ¼ 0.42, sr2 ¼ 0.48) for a non-standard high contact
1.0 ratio spur for one complete mesh cycle (Figure 5). The
20 LSR for the rack cutter tooth thickness factor of gear,
40 sr2 ¼ 0.48, is higher than that of the sr2 ¼ 0.42 at the
1.5 critical loading point SLPDTC (D).
1.3
Fni
ha þ 0.25 LSR ¼ ð15Þ
Fn
2.2
0 where Fni is contact load taken by the individual tooth
5m pair at the instantaneous contact and Fn is the total
normal force acting on the tooth.
1
10
Full round Load sharing ratio-based maximum fillet stress
The LSR-based maximum fillet stress ((st)max) of pinion
and gear due to load at the critical loading point
SLPDTC (D) is shown in Figure 6(a). Also, (st)max of
the pinion and gear is plotted against the contact pos-
ition for two different rack cutter tooth thickness factor
of gear (Sr2 ¼ 0.42, Sr2 ¼ 0.48) as shown in Figure 6(b)
and (c), respectively. (st)max of the pinion and gear is
not equal for a load at the critical loading point
SLPDTC (D) for Sr2 ¼ 0.42. Furthermore, (st)max is
determined for a set of six rack cutter tooth thickness
factor of gear and pinion and it is plotted in Figure 6(d).
It is observed that (st)max of the pinion and gear is equal
when the rack cutter tooth thickness factor of gear, Sr2
is 0.48. This balanced fillet stress condition is called as
optimized fillet stress with respect to the rack cutter
tooth thickness factor of gear.
Parametric study on non-standard high
contact ratio spur gears
A parametric study is conducted to determine the
improvement in the bending strength of non-standard
Marimuthu and Muthuveerappan 1143

Figure 5. Load sharing ratio for one mesh cycle (m ¼ 1 mm, z1 ¼ 40, i ¼ 1.5, a ¼ 20 , sr2 ¼ 0.42, 0.48, " ¼ 2.2, x1 ¼ 0, x2 ¼ 0,
ha ¼ 1 m, hf ¼ 1.3 m).

Figure 6. Effect of rack cutter tooth thickness factor of gear and pinion on the LSR and respective fillet stress (m ¼ 1 mm, z1 ¼ 40,
i ¼ 1. 5, a ¼ 20 , " ¼ 2.2, x1 ¼ 0, x2 ¼ 0). (a) (st)max due to load at critical loading point SLPDTC (D). (b) (st)max vs. contact position
for i ¼ 1.5, Sr2 ¼ 0.42. (c) (st)max vs. contact position for i ¼ 1.5, Sr2 ¼ 0.48. (d) (st)max vs. Rack cutter tooth thickness factor of gear
and pinion.

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1144 Proc IMechE Part C: J Mechanical Engineering Science 230(7–8)

high contact ratio spur gears based on the balanced

Effect of teeth number
fillet stress of pinion and gear. The gear parameters The LSR-based maximum fillet stress, (st)max, for a
considered for the parametric study are listed in load at the critical loading point is determined for the
Table 2. different teeth number of pinion (z1 ¼ 40, 50 and 60)
with gear ratio, i ¼ 1.5. Also, (st)max is plotted with
respect to rack cutter tooth thickness factor of pinion
Effect of gear ratio
and gear (Figure 8). It is observed that significant
To examine the influence of gear ratio, the LSR-based reduction of optimum (st)max is due to increase in
maximum fillet stress, (st)max, is plotted against the the teeth number of the pinion. But, the rack cutter
rack cutter tooth thickness factor of the pinion and tooth thickness factor of gear, sr2 increases marginally
gear as shown in Figure 7 with parameters m ¼ 1, when the teeth number of pinion increases based on
z1 ¼ 40, a ¼ 20 , x1 ¼ 0, x2 ¼ 0, i ¼ 1, 1.5 and 2. It is the optimum fillet stress condition. It is observed from
observed that the rack cutter tooth thickness factor of Figure 8 that the rack cutter tooth thickness factor of
gear, sr2 decreases due to increase in gear ratio based gear sr2 ¼ 0.48 for z1 ¼ 40, sr2 ¼ 0.486 for z1 ¼ 50, and
on the balanced (optimum) maximum fillet stress. For sr2 ¼ 0.489 for z1 ¼ 60.
i ¼ 1, optimum (st)max of the pinion and gear is equal
when sr2 ¼ 0.5. But sr2 decreased to 0.479 due to
increase in gear ratio, i ¼ 2.
Influence of pressure angle
To estimate the effect of pressure angle (a ¼ 17.5 , 20
and 22.5 ) on the LSR-based maximum fillet stress,
Table 2. Gear parameters for parametric study. (st)max is determined for different rack cutter tooth
thickness factor of the pinion and gear (Figure 9). It
Sl.No Parameters Values is noticed that, the increase in pressure angle results in
1 Gear ratio, i 1, 1.5, and 2 significant reduction of optimum (st)max for a load at
the critical loading point (SLPDTC). At the same time,
2 No. of teeth in pinion, z1 40, 50, and 60
rack cutter tooth thickness factor of gear, sr2 increases
3 Pressure angle, a (degree) 17.5 , 20 , and 22.5
due to increase in pressure angle based on the optimum
4 Addendum factor, ha 1.25, 1.3, and 1.35
(st)max. In Figure 9 it is shown that the rack cutter
5 Sþ Drives x1 ¼ 0.1, x2 ¼ 0 tooth thickness factor of gear sr2 ¼ 0.42 for a ¼ 17.5 ,
x1 ¼ 0.2, x2 ¼ 0 sr2 ¼ 0.48 for a ¼ 20 and sr2 ¼ 0.495 when a ¼ 22.5 .
6 S Drives x1 ¼ 0, x2 ¼ 0.1
x1 ¼ 0, x2 ¼ 0.2
Effect of addendum height
7 So Drives x1 ¼ 0.1, x2 ¼ 0.1
x1 ¼ 0.2, x2 ¼ 0.2 The LSR-based maximum fillet stress, (st)max, is esti-
mated for different addendum height (ha ¼ 1.25, 1.30

Figure 7. Effect of gear ratio on maximum fillet stress (m ¼ 1 mm, z1 ¼ 40, a ¼ 20 , x1 ¼ 0, x2 ¼ 0, i ¼ 1, 1.5, and 2).

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Marimuthu and Muthuveerappan 1145

Figure 8. Effect of teeth number (m ¼ 1 mm, i ¼ 1.5, a ¼ 20 , x1 ¼ 0, x2 ¼ 0, z1 ¼ 40, 50, and 60).

Figure 9. Effect of pressure angle (m ¼ 1 mm, z1 ¼ 40, i ¼ 1.5, x1 ¼ 0, x2 ¼ 0, a ¼ 17.5 , a ¼ 20 , a ¼ 22.5 ).

and 1.35) with a set of six rack cutter tooth thickness
factor of the pinion and gear (Figure 10). An increase
in the addendum height leads to an increase in the
average number of teeth in contact. It is observed
that the optimum (st)max increases significantly due
to increase in addendum height. But, the rack cutter
tooth thickness factor of gear, sr2 increases marginally
based on the optimum (st)max.
Effect of addendum modification factor
The LSR-based maximum fillet stress, (st)max is deter-
mined for different corrected gear drives, Sþ, S and
So drives, and it is plotted against rack cutter tooth
thickness factor of gear and pinion (Figures 11–13).
The sum addendum modification factor of the pinion
and gear is positive (x1 þ x2 > 0) for Sþ drives, nega-
tive (x1 þ x2 < 0) for S drives, and x1 þ x2 ¼ 0 for So
drives.
Sþ drives. Figure 11 shows the LSR-based maximum
fillet stress, (st)max with respect to rack cutter
tooth thickness factor of pinion and gear for the Sþ
drives. It is observed that positive addendum modifi-
cation results in significant reduction of optimum
(st)max, whereas the rack cutter tooth thickness

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1146 Proc IMechE Part C: J Mechanical Engineering Science 230(7–8)

Figure 10. The effect of addendum height (m ¼ 1 mm, z1 ¼ 40, i ¼ 1. 5, a ¼ 20 , x1 ¼ 0, x2 ¼ 0, ha ¼ 1.25, 1.3, 1.35).

Figure 11. Influence of positive addendum modification factor (m ¼ 1 mm, z1 ¼ 40, i ¼ 1.5, a ¼ 20 , ha ¼ 1.3, x1 ¼ 0, 0.1 and 0.2,
x2 ¼ 0).

factor of gear, sr2 increases marginally based opti- of critical root thickness. But, the rack cutter tooth
mum (st)max. From Figure 11 it can be seen that thickness of gear decreases for the optimum (st)max.
sr2 ¼ 0.482 for x1 ¼ 0.1, x2 ¼ 0 and sr2 ¼ 0.486 for From Figure 12, sr2 ¼ 0.477 for x1 ¼ 0, x2 ¼ 0.1 and
x1 ¼ 0.2, x2 ¼ 0. sr2 ¼ 0.474 for x1 ¼ 0, x2 ¼ 0.2.

S drives. The LSR-based maximum fillet stress,
(st)max, is estimated for S drives with respect to
rack cutter tooth thickness factor of the pinion and
gear as shown in Figure 12. The optimum (st)max
increases significantly due to increase in the negative
addendum modification factor because of reduction
So drives. The LSR-based maximum fillet stress is
determined for So drives with different rack cutter
tooth thickness factor of gear and pinion (Figure
13). It is observed that the optimum (st)max and the
rack cutter tooth thickness factor of gear increases
marginally for So drives. From Figure 13 it can be

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Marimuthu and Muthuveerappan 1147

Figure 12. Influence of negative addendum modification factor (m ¼ 1 mm, z1 ¼ 40, i ¼ 1. 5, a ¼ 20 , ha ¼ 1.3, x1 ¼ 0, x2 ¼ 0, 0.1,
0.2).

Figure 13. Effect of Maximum fillet stress for So drives (m ¼ 1 mm, z1 ¼ 40, i ¼ 1. 5, a ¼ 20 , ha ¼ 1.3, x1 ¼ 0, 0.1 and 0.2, x2 ¼ 0,
0.1 and 0.2).

seen that sr2 ¼ 0.4815 for x1 ¼ 0.1, x2 ¼ 0.1 and cutter tooth thickness factor of the pinion and gear. The
sr2 ¼ 0.4855 for x1 ¼ 0.2, x2 ¼ 0.2. following observations are made from this study.

1. The bending strength can be improved through

Conclusions
The present study attempts to determine the improve-
ment in the bending strength based on the balanced
(optimum) fillet stress of pinion and gear for non-stan-
dard high contact ratio spur gears. Also, a parametric
study is carried out to find the effect of some gear par-
ameters on optimum fillet stress with respect to the rack
modifying the rack cutter tooth thickness factor
of the pinion (Sr1 ¼ 0.52) and gear (sr2 ¼ 0.48)
based on the optimum fillet stress instead of stand-
ard rack cutter tooth thickness factor
(Sr1 ¼ Sr2 ¼ 0.5).
2. The rack cutter tooth thickness factor of gear
decreases due to increase in gear ratio. Also, the

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1148 Proc IMechE Part C: J Mechanical Engineering Science 230(7–8)

LSR-based optimum fillet stress decreases IMechE, Part D: J Automobile Engineering 2009; 224:
marginally. 631–643.
3. The optimum fillet stress decreases significantly 10. Prabhu Sekar R and Muthuveerappan G. An a
due to increase in teeth number of pinion and balanced maximum fillet stresses on normal contact
ratio spur gears to improve the load carrying capacity
gear.
through nonstandard gears. Mech Based Des Struct
4. The increase in pressure angle leads to significant
Mach 2015; 43: 150–163.
reduction of optimum fillet stress. But, the rack 11. ANSYS 12.1 user manual, Element references.
cutter tooth thickness factor of gear increases. Canonsburg, USA: ANSYS Inc., 2009.
5. The optimum fillet stress increases significantly
and there is a marginal rise of rack cutter tooth
thickness factor of gear due to increase in the
addendum height. Appendix
6. For Sþ drives, the increase in addendum modifi-
Notation
cation factor leads to a considerable reduction of
optimum fillet stress. But the optimum fillet stress ao center distance (mm)
increases for S drives and So drives. AF length of path of contact
b face width (mm)
In short, the increase in gear ratio, teeth number, E Young’s modulus (GPa)
pressure angle and positive addendum modification Fn normal load (N)
factor results in significant improvement in the bend- ha addendum of gear tooth
ing strength for the non-standard high contact ratio har addendum of rack cutter
spur gear. hf dedendum of gear tooth
hfr dedundum of rack cutter
Declaration of Conflicting Interests i gear ratio
The author(s) declared no potential conflicts of interest with m module (mm)
respect to the research, authorship, and/or publication of p pitch (mm)
this article. pb base pitch
ra radius of addendum circle (mm)
Funding rb radius of base circle (mm)
The author(s) received no financial support for the research, rA radii at LPTC of pinion (mm)
authorship, and/or publication of this article. rB radii at FLPDTC of pinion (mm)
rC radii at FHPDTC of pinion (mm)
References rD radii at SLPDTC of pinion (mm)
1. Elkholy AH. Tooth load sharing in high contact ratio rE radii at SHPDTC of pinion (mm)
spur gears. J Mech Transm-Automat 1985; 107: 11–16. rF radii at addendum circle of pinion (mm)
2. Chuen-huei L, Hsiang HL and Townsend DP. Effect of sr1 nonstandard rack cutter tooth thickness
contact ratio on spur gear dynamic load with no tooth factor of pinion
profile. J Mech Des 1996; 118: 439–448. sr2 nonstandard rack cutter tooth thickness
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