Design and Finite Element Analysis of Helical Gear-Pinion Mechanisms: Assessing Mechanical Behavior

This paper investigates the design and performance analysis of a helical gear-pinion system intended for a reducer gearbox, which operates at a pinion speed of 1800 rpm and a power supply of 5 hp under moderate shock conditions for 8 to 10 hours daily. Using carbon steel (SAE 3150) for both parts, the study runs mathematical modelling to assess critical parameters and then designs it through SolidWorks integrated with GearTrax. Finite Element Analysis (FEA) conducted in ANSYS assesses the mechanical behavior under load, revealing a maximum deformation of 1.4672×10-2 mm, maximum directional deformation (X-axis) of 1.2994×10-2 mm, maximum equivalent (von Mises) stress of 125.79 MPa, and maximum principal stress of 138.99 MPa, all within acceptable limits for the material. The findings indicate that the gear-pinion system can operate reliably without premature failure. This research contributes to understanding gear design and performance, providing a foundation for future studies on material optimization and real-world operational conditions.