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.