This study emphasizes the importance of a closed-loop approach togear design and manufacturing to assure designed root fillet shapes are attained in production, and gears meet the design intent.

While designing gear and spline teeth, the root fillet area and the corresponding maximum tensile stress are primary design considerations for the gear designer. Root fillet tensile stress may be calculated using macro-geometry values such as module, minor diameter, effective fillet radius, face width, etc.

In this paper, an accurate FEM analysis has been done of the “true” stress at tooth root of spur gears in the function of the gear geometry. The obtained results confirm the importance of these differences.