Comparative study of Aluminum alloy, Gray CI, structural steel and Low alloy steel AISI 4140 spur gears using FEA and material testing

Spur gears are commonly used for power transmission in mechanical systems. This research analyzes and compares spur gears made of four different materials - Aluminum alloy, Gray Cast Iron, Structural steel and low alloy steel AISI 4140. FEA was conducted to determine the effects of deformation, von Mises stress, and strain on the gearbox components, which indicated that they will perform adequately in relation to the loads associated with vehicle operation. This comparison evaluated the mechanical behavoir within the operating conditions for gearbox components, such as von Miss stress and Von Miss strain. The FEA and mechanical testing demonstrated that these types of materials had comparable properties. The comparative analysis of mechanical properties of these materials and the design of the gearbox should be useful in helping to determine appropriate material selection for the manufacture of spur gears to be used in mechanical applications to transmit power.