Finite element analysis of stress distribution in optimized gear systems

Gears are fundamental mechanical components used in a wide range of power transmission applications. Optimizing gear systems for stress distribution is essential to enhance performance, reliability, and durability. This paper presents a detailed finite element analysis (FEA) of stress distribution in spur and helical gear systems with varying design parameters. A comparative study is conducted between conventional and optimized gear profiles, focusing on material selection, pressure angles, and tooth geometry modifications. The modeling and simulation were carried out using ANSYS Workbench, where 3D models were meshed with high precision and boundary conditions were applied replicating realistic operational loads. Von Mises stress contours, contact stress, and deformation fields were analyzed under static loading conditions. The results demonstrated that optimized gear designs significantly reduced stress concentrations, particularly at the root of the gear teeth, and improved the load-carrying capacity. The study concludes with recommendations for gear optimization based on FEA and outlines future prospects in fatigue analysis and multi-body dynamics simulation.