Modeling a HCR Gear with Variable Thickness of the Thin Hard Coating on the Tooth Surface for Fem Analysis

Abstract This work presents a computer model of HCR gear wheels with thin hard coatings of variable thickness. The coating thickness fluctuates along tooth depth due to limited technological space, particularly at the dedendum. Experimental studies revealed coating destruction occurs mainly at the tooth dedendum when thickness falls below 2 μm, leading to peeling. The varying stiffness between tooth addendum and dedendum affects coating strength and load-bearing capacity. The model, developed in SolidWorks CAD, accounts for HCR gearing kinematics, contact path geometry, and simultaneous multi-pair tooth engagement.